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1. SSH2IdXI NOLLV 3IOd 1IOO 3 409009999090909000000909090909000000090999090000009 9999900000000000000000Q00000000000Q00000000Q0QQQQ 400000000000000000000000000000000000000000000000000000000000000000000000000000000000000 0 0 9 99 9 999099999 9 999999999 99999 09999 99999 CX Q lt gt Q3 CS c CS CS d CS CS CS a CS cS cS CS CS CS cS CS cS CS cS CS CS C CS CS GS GS cS gt gt C2 2400000000000000000000000000000000000000000000000000000000000000000 5 e e e N o c N gt tc 7 53 n oO T I ra o lt N N tc N 2 o S S oc IOM Revision Log 28 June 2007 Updated flow controller mounting instructions 24 Aug 2006 Various Formatting Changes and Corrections 24 Aug 2006 29 30 Updated Electrical Data 24 Aug 2006 17 33 Added Motorized Water Valve Cautions 10 Aug 2005 First Published TERTE e z ENERGY STAR PARTNER 7300 S W 44th Street Oklahoma City OK 73179 Phone 405 745 2920 NE Fax 405 745 6620 97 0048
2. 10 8 11 9 6 7 8 1 5 1 5 9 14 0 15 2 9 0 10 2 6 7 7 9 Operation Not Recommended Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 20070 Air Temp Rise F DB Air Temp Rise F DB PREVENTIVE MAINTENANCE Water Coil Maintenance Direct ground water applications only If the system is installed in an area with a known high mineral content 125 P P M or greater in the water it is best to establish a periodic maintenance schedule with the owner so the coil can be checked regularly Consult the well water applications section of this manual for a more detailed water coil material selection Should periodic coil cleaning be necessary use standard coil cleaning procedures which are compatible with the heat exchanger material and copper water lines Generally the more water flowing through the unit the less chance for scaling Therefore 1 5 gpm per ton 2 0 per kW is recommended as a minimum flow Minimum flow rate for entering water temperatures below 50 F 10 C is 2 0 gpm per ton 2 6 per kW Water Coil Maintenance All other water loop applications Generally water coil maintenance is not needed for closed loop systems However if the piping is known to have high dirt or debris content it is best to establish a periodic maintenance schedule with the owner so the water coil can be checked regularly Dirty installations are typically the result of deteriorati
3. meta i o me 17 eepe eo o ae 17 S an ens ve7 pro o 155 s Fin pna me 57 o vm a7 EE EE ee eee 4 Isometric View Top View o 2 i 2 28 6mm 2 HWG In J Knockout Q water Out 7 8 22 2mm Knockout Suction L 9 Qu Line K 1 D2 Left Side View 1477 Front View 29 9mm Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 20070 DIMENSIONS GT G SPLIT 50YCS amp GT S SPLIT 38WQS SERIES GT G Split BOYCS Series Overall Cabinet Water Connections Electrical Knockouts A B 1 Water In 8 2 HWG Out D E F G 3 Size 4 Size H 1 Width Height Depth i Swivel Out HWG In HWG Out Suction Liquid Suction Liquid org in 224 193 256 24 54 13 9 16 9 a 5 14 cm 5
4. 979944 02 1972M 105095 ubi aX Jeduin 3nd 4 404 umoys euis wely 9 pue DIN 3snuu y 0 4030 4 254 YMS Ajddns yun ueu 123231 Ajj euuau 10ssa4dulo 1 40326300 10559490 29 O N cONTOO0896 FON 0 lt 2 0 uva bTTO TO EN Dd YOLNAIALSIA 1 09 0 80 090 810 11145 e e e e o c N gt tc 7 A oO I o lt t 5 N N tr N a o S 42 t TYPICAL WIRING DIAGRAM 38WQS UNITS WITH CXM BOARD External Pump 1 2 hp 208 230 1 60 69828103 DRAWING NO Power Supply Refer to Data Plate Use copper conductors only See Note 2 SEE NOTE 3 SEE NOTE 9 24V from Control Transformer Test Pins Compressot RED Typical Relay HP Heat Pump 7 RED T stat andler NOTE 5 SEE BLU 4 BRN Dip Switch JW3 GRY SEE 1 Low T i UPS 2 FPI NOTE4 Used GRY
5. 79 a7 a2 oo s e 5 5 T T5 155 Gross coolina capacity MBtuh Sensible heat capacity MBtuh Bypass factor Utilizing the Existing Air Handler or Coil R22 units only It is recommended that a new coil or air handler be installed with any geothermal split system compressor section due to the low initial cost of the additional equipment versus the reliability and benefit of new technology increased reliability and warranty However if the existing air handler must be used R22 systems only the following conditions apply If the existing coil currently uses an orifice the orifice must be removed and replaced with a TXV If the coil utilizes capillary tubes it will not operate properly with the geothermal split system and should be replaced If life expectancy of indoor coil and associated components fan cabinet etc is less than 7 10 years indoor section should be replaced Residential Split GOHz R22 amp R410A Geothermal Heat Pumps Rev 28 June 2007D INSTALLATION NOTICE Failure to remove shipping brackets from spring mounted compressors will cause excessive noise and could cause component failure due to added vibration The installation of water source heat pump units and all associated components parts and accessories which make up the installation shall be in accordance with the regulations of ALL authorities having jurisdiction and M
6. Thermister provides freeze protection for WATER When using ANTI FREEZE solutions cut JW3 jumper Typical heat pump thermostat wiring shown Refer to thermostat Installation Instructions for wiring to the unit T stat wiring must be Class 1 and Voltage rating equal to or greater than unit supply voltage 24V Alarm Signal shown For Dry Alarm Contact cut JW1 Jumper and Dry Contact will be available between 11 and AL2 Transformer secondary ground via CXM board standoffs amp screws to Control Box Ground available from top two standoffs as shown FP2 Wiring a Clip VIO wire Loop at X b Install FP2 Thermistor shipped with unit in the Air Handling section on copper tube between distributor amp expansion valve c Wire VIO lead from FP2 to VIO lead clipped in note a as shown 9 PTCR use only when applicable Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 2007D CXM CONTROLS CXM Control For detailed control information see CXM DXM Application Operation and Maintenance AOM manual part 9780003 08 Field Selectable Inputs Test mode Test mode allows the service technician to check the operation of the control in a timely manner By momentarily shorting the test terminals the CXM control enters a 20 minute test mode period in which all time delays are sped up 15 times Upon entering test mode the status LED will flash a code representing the last fault For di
7. at 15 F 10 C Calculation is as follows 30 F 15 F 15 F 1 C 9 C 10 All alcohols should be premixed and pumped from a reservoir outside of the building when possible or introduced under the water level to prevent fumes Calculate the total volume of fluid in the piping system Then use the percentage by volume shown in Table 1 for the amount of antifreeze needed Antifreeze concentration should be checked from a well mixed sample using a hydrometer to measure specific gravity Low Water Temperature Cutout Setting CXM or DXM Control When antifreeze is selected the FP1 jumper JW3 should be clipped to select the low temperature antifreeze 13 F 10 6 C set point and avoid nuisance faults see Low Water Temperature Cutout Selection in this manual NOTE Low water temperature operation requires extended range equipment Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 20070 GROUND LOOP HEAT PUMP APPLICATIONS Table 1 Approximate Fluid Volume U S gal L per 100 of Pipe Fluid Volume gal liters per 100 30 meters Pipe Pipe Size Volume gal liters 1 4 1 15 3 Copper 1 25 6 4 23 8 2 5 9 2 34 3 Rubber Hose 1 3 9 14 6 3 4 IPS 0811 2 8 10 4 1 iPS SDR11 4 5 16 7 1 25 IPS SDR11 8 0 29 8 1 5 IPS SDR11 10 9 40 7 Polyethylene 2 IPS SDR11 18 0 67 0
8. 1 25 IPS SCH40 8 3 30 9 1 5 IPS SCH40 10 9 40 7 2 IPS SCH40 17 0 63 4 Unit Heat Exchanger Typical 1 0 3 8 10 Dia x 3ft tall 254mm x 91 4cm tall 10 37 9 Figure 8 Loop Connection Outdoor Compressor Section P T Ports ojo 4 Alli Air Pad with access hole Flow Controller Insulate all piping with 1 2 13mm closed cell insulation Backfill carefully to avoid stress on piping and flow controller connection Header Pit Table 2 Antifreeze Percentages by Volume Type Figure 7 Loop Connection Indoor Compressor Section To Loop Flow Controller Unit Power Disconnect Air Pad or Extruded polystyrene insulation board NOTICE Cabinet opening around loop piping outdoor compressor section must be sealed to prevent entry of rodents that could potentially damage unit wiring by chewing on the insulation NOTICE Outdoor compressor section may not be tilted more than 5 degrees from level Damage to the compressor or stress on the loop piping could result if unit is tilted concrete pad anchor posts and or soil compaction may be required to avoid tilting as ground settles Minimum Temperature for Low Temperature Protection 10 F 12 2 C 15 F 9 4 C 20 F 6 7 C 25 F 3 9 C Methanol 100 USP food grade Propylene Glycol Ethanol
9. 173 183 177 187 182 192 Full Load Heating without HWG active Super heat Discharge Pressure PSIG 282 302 285 305 289 309 318 338 321 341 324 344 360 380 364 384 368 388 407 427 411 431 415 435 Sub 8 13 8 13 9 14 12 17 12 17 12 17 12 17 12 17 12 17 13 18 13 18 14 19 cooling Water Temp Drop F 11 3 13 3 8 5 10 5 5 7 7 7 18 2 20 2 13 9 15 9 9 6 11 6 Operation Not Recommended Table 15 R 22 Typical Unit Operating Pressures and Temperatures Entering Water Temp F GPM ton Suction Pressure PSIG Full Load Cooling without HWG active Discharge Pressure PSIG 100 117 92 109 88 104 145 170 130 155 125 150 180 200 169 187 160 180 230 272 215 248 208 240 Super heat 9 12 18 12 18 12 18 10 15 10 15 10 15 8 12 8 12 Water Temp Rise F Air Temp Drop F DB Suction Pressure PSIG Based on Nominal 400 CFM per ton per circuit ariflow and 70 F EAT heating and 80 67 F cooling Cooling air and water numbers can vary greatly with changes in humidity Water temperature difference based upon 1 5 3 GPM per ton of active circuit water flow Using liquid line pressure Full Load Heating without HWG active Discharge Pressure PSIG 163 183 165 185 167 186 175 202 178 206 180 208 215 250 203 235 200 235 Sub Super heat 5 10 5 10 5 10 cooling Water Temp Drop
10. D Notes 1 Compressor 2nd stage connection is not part of the terminal strip onthe CXM board A wire nut connection is required between the compressor solenoid valve and N I M 2 Y2 connection on N I M is not used for single stage units 3 Do not connect W from the board to the N I M through the middle of the back plate Mark the position of the back plate mounting holes and drill holes with a 3 16 5mm bit Install supplied anchors and secure plate to the wall Thermostat wire must be 18 AWG wire Wire the appropriate thermostat as shown in Figures 28a through 28c to the low voltage terminal strip on the CXM control board Practically any heat pump thermostat will work with these units provided it has the correct number of heating and cooling stages Figure 28b Typical Thermostat Wiring Single Stage Units 2 Heat 1 Cool From Compressor Solenoid Valve CXM Board Compressor Section TSTAT CCPRHO1 or BBPRHO1 e vv FV4 Air Handler 2 Yi w2 Remove Jumper for Dehum Mode Notes 1 Thermostat DIP switches must be configured for two speed heat pump 2 Compressor 2nd stage connection is not part of the terminal strip on the CXM board A wire nut connection is required between the compressor solenoid valve and Y Y2 connection at the fan coil Figure 28b Typical Thermostat Wiring Infinity Evolution Controls From Co
11. Residential Split 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 2007D GROUND LOOP HEAT PUMP APPLICATIONS Earth loop temperatures can range between 25 and 110 F 4 to 43 C Flow rates between 2 25 and 3 per ton 2 41 to 3 23 per kW of cooling capacity is recommended in these applications Test individual horizontal loop circuits before backfilling Test vertical U bends and pond loop assemblies prior to installation Pressures of at least 100 psi 689 kPa should be used when testing Do not exceed the pipe pressure rating Test entire system when all loops are assembled Flushing the Earth Loop Once piping is completed between the unit Flow Controller and the ground loop Figures 7 and 8 the loop is ready for final purging and charging A flush cart with at least a 1 5 hp 1 1 kW pump is required to achieve enough fluid velocity in the loop piping system to purge air and dirt particles An antifreeze solution is used in most areas to prevent freezing All air and debris must be removed from the earth loop piping before operation Flush the loop with a high volume of water at a minimum velocity of 2 fps 0 6 m s in all piping The steps below must be followed for proper flushing 1 Fill loop with water from a garden hose through the flush cart before using the flush cart pump to insure an even fill 2 Once full the flushing process can begin Do not allow the water level in the flush cart tan
12. Water Flow Control Regulator Pressure Water Out Water In Shut Off Valve Optional Filter Boiler Drains P T Plugs Residential Split 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 2007D WATER QUALITY STANDARDS Table 3 Water Quality Standards Water Quality HX Closed Parameter Material Recirculating Open Loop and Recirculating Well Scaling Potential Primary Measurement Above the given limits scaling is likely to occur Scaling indexes should be calculated using the limits below pH Calcium Hardness Method Index Limits for Probable Scaling Situations Operation outside these limits is not recommended Scaling indexes should be calculated at 150 F 66 C for direct use and HWG applications and at 90 32 for indirect HX use A monitoring plan should be implemented Ryznar 6 0 7 5 Stability Index If 27 5 minimize steel pipe use Langelier 0 5 to 40 5 If lt 0 5 minimize steel pipe use Based upon 150 F 66 C HWG and Saturation Index Direct well 85 F 29 C Indirect Well HX pH 7 5 and Ca Hardness 100ppm Iron Fouling Fe Ferrous 0 2 ppm Ferrous Bacterial Iron potential If Fe ferrous gt 0 2 ppm with pH 6 8 O2 5 ppm check for iron bacteria 0 5 ppm of Oxygen Above this level deposition will occur Corrosion Prevention 6 8 5 6 8 5 pH Monitor treat as needed lt 0 5 At 25 gt
13. 2 lockout code 5 Condensate overflow The condensate overflow sensor must sense overflow level for 30 continuous seconds to be recognized as a CO fault Condensate overflow will be monitored at all times CO lockout code 6 Over under voltage shutdown An over under voltage condition exists when the control voltage is outside the range of 19VAC to 30VAC Over under voltage shut down is a self resetting safety If the voltage comes back within range for at least 0 5 seconds normal operation is restored This is not considered a fault or lockout If the CXM is in over under voltage shutdown for 15 minutes the alarm relay will close Over under voltage shut down code 7 Unit Performance Sentinel UPS patent pending The UPS feature indicates when the heat pump is operating inefficiently A UPS condition exists when a In heating mode with compressor energized FP2 is greater than 125 F 52 C 30 continuous seconds b In cooling mode with compressor energized FP1 is greater than 125 F 52 C for 30 continuous seconds In cooling mode with compressor energized FP2 is less than 40 F 4 5 C for 30 continuous seconds If a UPS condition occurs the control will immediately go to UPS warning The status LED will remain on as if the control is in normal mode Outputs of the control excluding LED and alarm relay will NOT be affected by UPS The UPS condition cannot occur during a compressor off cyc
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15. 25 38 29 Must not be denatured with any petroleum based product 21 16 10 25 22 15 25 20 14 Residential Split 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 20070 GROUND WATER HEAT PUMP APPLICATIONS INDOOR COMPRESSOR SECTION ONLY Open Loop Ground Water Systems Indoor Compressor Section Only The outdoor version of the compressor section may not be used with open loop systems due to potential freezing of water piping Typical open loop piping is shown in Figure 9 Shut off valves should be included for ease of servicing Boiler drains or other valves should be tee d into the lines to allow acid flushing of the heat exchanger Shut off valves should be positioned to allow flow through the coax via the boiler drains without allowing flow into the piping system P T plugs should be used so that pressure drop and temperature can be measured Piping materials should be limited to copper PVC 5 80 Note Due to the pressure and temperature extremes PVC SCH4O0 is not recommended Water quantity should be plentiful and of good quality Consult Table 3 for water quality guidelines The unit can be ordered with either a copper or cupro nickel water heat exchanger Consult Table 3 for recommendations Copper is recommended for closed loop systems and open loop ground water systems that are not high in mineral content or corrosiveness In conditions anticipating heavy scale formation
16. 8 When testing is complete set system to maintain desired comfort level 9 BE CERTAIN TO FILL OUT AND RETURN ALL WARRANTY REGISTRATION PAPERWORK Note If performance during any mode appears abnormal refer to the CXM section or troubleshooting section of this manual To obtain maximum performance the air coil should be cleaned before start up A 10 solution of dishwasher detergent and water is recommended WARNING A WARNING When the disconnect switch is closed high voltage is present in some areas of the electrical panel Exercise caution when working with energized equipment A CAUTION A CAUTION Verify that ALL water control valves are open and allow water flow prior to engaging the compressor Freezing of the coax or water lines can permanently damage the heat pump Figure 29 Test Mode Pins Short test pins BR BRG cca cc together to enter Test Mode and speed up C T 4 timing and delays for 20 Jw3 4 1 Jw2 4 Residential Split 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 20070 UNIT OPERATING CONDITIONS Table 12a Two Stage R 410A Compressor Table 13 Water Temperature Change Section Coax Water Pressure Drop Through Heat Exchanger Rise Cooling Drop Heating F 9 12 5 6 7 Pressure Drop psi Water Flow gpm 50 F 70 F For Closed Loop Ground Source or Closed Loop Systems at 3 gpm p
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18. using a UV resistant paint or covering to prevent deterioration from sunlight When passing refrigerant lines through a wall seal opening with silicon based chaulk Avoid direct contact with water pipes duct work floor joists wall studs floors or other structural components that could transmit compressor vibration Do not suspend refrigerant tubing from joists with rigid straps Do not attach line set to the wall When necessary use hanger straps with isolation sleeves to minimize tranmission of line set vibration to the structure Installing the Lineset at the Compressor Section Braze the line set to the service valve stubs as shown in Figure 10 On installations with long line sets copper adapters may be needed to connect the larger diameter tube to the stubs Nitrogen should be circulated through the system at 2 3 psi 13 8 20 7 kPa to prevent oxidation contamination Use a low silver phos copper braze alloy on all brazed connections Compressor section is shipped with a factory charge Therefore service valves should not be opened until the line set has been leak tested purged and evacuated See Charging the System Table 4 Lineset Diameters and Charge Information 3 8 7 8 3 8 vss mens 104 2 95 89 2 52 7 8 Basic charge includes only the amount required for the condensing unit and the evaporating coil An additional amount should be added allowing 0 602 per ft for 3 8 0 60 per cm and 1
19. 01 The Manufacturer works continually to improve its products As result the design and specifications of each product at the time for order be changed without notice and may not be as described herein Please contact Manufacturer s Customer Service Department at 1 405 745 2920 for Specific information on the current design and specifications Statements and other information contained herein are not express warranties and do not form the basis of any bargain between the parties but are merely Manufacturer s opinion or commendation of its products The management system governing the manufacture of The Manufacturer s products is ISO 9001 2000 certified LSB Inc 2005 Rev 28 June 2007D
20. 1 C vs 12 Bad thermistor Check temp and impedance correlation per chart Normal airside applications will require 30 F 1 C only x x Condensate Fault Code 6 Blocked Drain Check for blockage and clean drain Check trap dimensions and location ahead of vent Poor Drainage Check for piping slope away from unit Check slope of unit toward outlet Poor venting Check vent location Moisture on sensor Check for moisture shorting to air coil Over Under Voltage Under Voltage Check power supply and 24VAC voltage before and during Code 7 operation Auto resetting Check power supply wire size Check compressor starting Need hard start kit Check 24VAC and unit transformer tap for correct power supply voltage Check power supply voltage and 24VAC before and during Over Voltage operation Check 24VAC and unit transformer tap for correct power supply voltage Unit Performance Sentinel Code 8 Heating mode 2 gt 125 52 Check for poor air flow or overcharged unit Cooling Mode 1 gt 125 52 OR FP2 40 F 4 C No compressor operation See Only fan operates Check for poor water flow or air flow No Fault Code Shown Compressor Overload Check and Replace if necessary Control board Reset power and check operation Dirty Air Filter Check and Clean air filter Unit in Test Mode Reset power or wait 20 minutes for auto exit Unit may be ove
21. 17 7 11 6 13 6 7 6 9 6 374 394 360 380 346 366 473 493 458 478 441 461 14 6 16 6 10 7 12 7 6 9 8 9 13 6 15 6 9 9 11 9 6 2 8 2 Full Load Cooling without HWG active Discharge Super Sub Water Temp Pressure i ise PSIG heat cooling Rise F 18 23 9 14 18 23 8 13 18 23 8 13 22 1 24 1 16 8 18 8 10 5 12 5 153 173 145 165 135 155 222 242 13 18 10 15 208 228 13 18 9 14 194 214 14 19 9 14 299 319 8 13 280 300 8 13 263 283 8 13 388 408 6 11 13 18 367 387 7 12 8 13 347 367 7 12 8 13 21 9 23 9 16 1 18 1 10 3 12 3 13 18 12 17 12 17 21 5 23 5 15 8 17 8 10 12 20 5 22 5 14 9 16 9 9 3 11 3 486 506 6 11 13 18 465 475 7 12 8 13 444 464 7 12 8 18 Full Load Cooling without HWG active Discharge Super Sub Pressure heat cooling PSIG Water Temp Rise F 187 207 167 187 147 167 18 23 18 23 18 23 23 28 21 26 20 25 20 7 22 7 15 5 17 5 10 2 12 2 245 265 18 18 19 24 227 247 18 18 18 23 208 228 14 19 16 21 314 334 9 14 17 22 294 314 9 14 16 21 274 294 10 15 14 19 401 421 8 13 16 21 379 399 8 13 15 20 357 377 9 14 18 18 14 19 18 18 12 17 20 9 22 9 15 6 17 6 10 2 12 2 20 5 22 5 15 2 17 2 9 9 11 9 19 2 21 2 14 3 16 3 9 3 11 3 502 522 8 13 477 497 8 13 452 472 9 14 Air Temp Drop F DB 18 24 19 25 19 25 18 24 19 25 19 25 18 24 18 24 18 24 17 23 17 23 17 23 16 22 16 22 16 22 Air Temp Drop F
22. 20 68 1544 188 302 6 1562 18 320 3260 1 338 31 00 f 1598 16 4 392 2660 5 s 428 241 8 464 2190 9 482 2080 80 1760 126 16 608 1500 86 1868 104 19 662 13 07 89 192 2 094 90 1940 09 94 2012 08 2048 02 98 2084 0 72 2102 0 70 101 2138 0 66 3 932 681 104 2192 060 47 166 404 2462 0 111 2 2372 0 46 123 253 4 0 36 Rev 5 23 00 m CXM Thermostat Details Thermostat Compatibility Most all heat pump thermostats can be used with the CXM control However Heat Cool stats are NOT compatible with the CXM Anticipation Leakage Current Maximum leakage current for Y is 50 mA and for W is 20 Triacs can be used if leakage current is less than above Thermostats with anticipators can be used if anticipation current is less than that specified above Thermostat Signals Y and W have a 1 second recognition time when being activated or being removed and are direct pass through signals but are monitored by the micro processor and C are from the transformer AL1 and AL2 originate from the alarm relay A is paralleled with the compressor output for use with well water solenoid valves The Y 1 4 quick connect is a connectio
23. 4402 6 3905 ONIHSV14 10103201 Zd4 Td4 2 i 8 3002 2 8 3002 5NIHsSV1H NI 1531 _ e Id 1591 NI NMOG LOHS ES 5 4 4 3802 SNTIDAD 4 3802 ONIHSV14 1531 22101 _ T 21 9 3002 ONTIDAD 9 3905 ONIHSV14 NI LINYA 02 1531 259 S 3002 S 3002 ONIHSV14 AYOWAW NI 244 IAOW 1531 ET b 3002 5NIT242 3009 SNIHSV 14 NI 1531 3002 3905 ONIHSV14 NI L10V4 d1 3GOW 1531 119 V oo oez eoz i 3002 3002 ONIHSV14 NI LINYA 1531 1 09 022 802 d dH E T 3009 T 3009 ONIHSV14 NI L1NV4 3 1531 Aiddns feuondo CNIW ST 8314 035010 40 HSV 14 MOIS NMOG LNHS 39V L10A 3i30Nn H3AO xn LL 935075 1593 1005201 V 1 N3dO HSV 14 MOIS 1 NadO 440 SI WX S 236 SZ N3dO 23S 5 035010 31042 NO SNINSVM Sdn M IAOW WWYON PN VL c8O 1 16 i N3dO NO IAOW TVWHON OQ 1201941 lt 8 oped P AV Iu NOILV33dO 30 NOLLdT42S3G Joyoece uny 53809 LINVA YATIONLNOD WX Jo 55215 eq sNW 3e35 jeuondo Je
24. F 52 C and is located on the HWG heat exchanger Water In line If the HWG is connected incorrectly or if circulation is reversed the aquastat will sense leaving water temperature and prevent HWG operation UNDER NO CIRCUMSTANCES SHOULD THE LIMIT BE DISCONNECTED OR REMOVED Full load conditions could drive hot water tank temperatures far above desirable temperature levels if the aquastat has been disconnected or removed Figure 16 HWG Double Tank Installation Indoor Compressor Section Hot Outlet to house Cold Inlet lt 1 E Upper element to 130 F 54 or owner aT preference U Powered Shut Off Valves with Waste Vent at high point Cold Inlet from Domestic supply Hot Outlet Water Heater Lower element to 120 F Unpowered 49 C Water Heater Tee and Drain sn Insulated water lines 5 8 OD 50 ft 15m maximum Residential Split 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 2007D HOT WATER GENERATOR Figure 17 Alternate HWG Piping with concentric coaxial fitting part 4569619804 not included with unit Indoor Compressor Section Hot Outlet Cold Inlet 49 54 C Waste Vent Coupling at high point Lower element to 100 110 F 38 43 Insulated water lines 5 8 OD 50 ft 15m maximum Coaxial 5 Fitting The heat pump water piping pump and hot water tank should
25. JW2 Off On VIO FP2 Low Temp VIO BRN o A o Status RVS LED ORG Rh Not Used CXM SEE d SEE NOTE 6 Microprocessor NOTE 6 for Control Logi Dry Contact DWG 69828103 Alarm UNIT SPLIT WSHP SIZES 018 060 POWER 208 230 1 60 PCN 02 0100 DATE 4 9 02 REV D NOTES Factory line voltage wiring Factory low voltage wiring Field line voltage wiring Field low voltage wiring Printed Circuit Trace Relay Contactor Coil Solenoid Coil Temperature Switch High Pressure Switch AL Low Pressure Switch CB Alarm Relay Contacts Circuit Breaker Legend e Thermistor Ground Compressor Contactor Crankcase Heater Compressor Run Capacitor Flow Control Relay Sensor Water Coil Freeze Protection Sensor Air Coil Freeze Protection High Pressure Switch Jumper Wire for Alarm Loss of Charge Pressure Switch Low Temperature Switch Field Wiring Terminal Block Positive Temp Coefficient Relay Reversing Valve Solenoid Transformer Water Valve 1 Compressor thermally protected internally 2 wiring to the unit must comply with NEC and local codes 3 For operation of field installed flow controller disconnect wire nuts from BLU leads and connect flow controller wire to BLU leads Danger line voltage Disconnect power to unit before making this connection Warning do not operate pump unless it has been connected to a water source
26. Residential 208 230V units are factory wired for 230V operation unless specified otherwise Loop water piping is complete and purged of air Water piping is clean Antifreeze has been added if necessary Entering water and air Insure that entering water and air temperatures are within operating limits of Table 10 Low water temperature cutout Verify that low water temperature cut out on the CXM DXM control is properly set Unit fan Manually rotate fan to verify free rotation and insure that blower wheel is secured to the motor shaft Be sure to remove any shipping supports if needed DO NOT oil motors upon start up Fan motors are pre oiled at the factory Check unit fan speed selection and compare to design requirements Condensate line Verify that condensate line is open and properly pitched toward drain pump is disconnected unless piping is completed and air has been purged from the system Water flow balancing Record inlet and outlet water temperatures for each heat pump upon startup This check can eliminate nuisance trip outs and high velocity water flow that could erode heat exchangers Unit air coil and filters Insure that filter is clean and accessible Clean air coil of all manufacturing oils Unit controls Verify that CXM field selection options are properly set Low voltage wiring is complete Blower speed is set Service access panels are in place SYSTEM CHECKOUT System water temperature Check water tem
27. Reversing Valve Hot Gas from Compressor Field connection of Hot Water lineset Open Valves CW Close valves CCW as looking up from underneath Residential Split 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 2007D HWG MODULE REFRIGERATION INSTALLATION OUTDOOR COMPRESSOR SECTION ONLY Figure 20 HWG Module Wiring A WARNING WARNING The HWG module is an appliance that operates in conjunction with the heat pump system the hot water system and the electrical system Installation should only qe be performed by skilled technicians with appropriate training and experience The Ee installation must be in compliance with local codes and ordinances Local plumbing and electrical building codes take precedence over instructions contained herein The Manufacturer accepts no liability for equipment damaged and or personal injury arising from improper installation of the HWG module Power Supply Refer to Data Plate Use copper L2 conductors only See Note 2 LI TI BLK Provide a safety disconnect switch near the HWG module A CAUTION CAUTION The HWG module must be A CAUTION A CAUTION Locate Refrigerant lines to avoid installed in an area that is not subject to accidental damage by lawnmowers or children freezing temperatures NOTICE Make sure the compressor discharge line is connected to the Hot Gas In stub on the Heat Rec
28. SNIBIM INIT 07314 97314 1 480129 SNIEIM 48012941 95937 ino 1331 9m 19 02 cadar quia 25 LAN 0108141 14 1 09 022 802 790 920 HOOQNI 11145 Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 20070 34 TYPICAL WIRING DIAGRAM 50YCS UNITS WITH CXM BOARD A4 J 1 cdd 3 326300 10 9 LON 335 21601 0 305 key m 105592044 9 aas WEN ul 1 30 1n0AV1 pesn 30N NOLOANNOD 1031405 SAY 9MH 4007 o A o wig EO Qu OIA 212 X 243 45 T T OIA som Y punog AUS gt 50 4019V1NO2 PILON Tdi s wr ur Qn i ees Or Ng vj 201 Lo ma 3 15 1 peua aad gay mei Je pueH 6
29. be located where the ambient temperature does not fall below 50 F 10 Keep water piping lengths at a minimum DO NOT use a one way length greater than 50 ft 15 m All installations must be in accordance with local codes The installer is responsible for knowing the local requirements and for performing the installation accordingly DO NOT connect the pump wiring until Initial Start Up section below Powering the pump before all installation steps are completed will damage the pump Water Tank Preparation 1 Turn off power or fuel supply to the hot water tank 2 Connect a hose to the drain valve on the water tank 3 Shut off the cold water supply to the water tank 4 Open the drain valve and open the pressure relief valve or a hot water faucet to drain tank When using an existing tank it should be flushed with cold water after it is drained until the water leaving the drain hose is clear and free of sediment 6 Close all valves and remove the drain hose 7 Install HWG water piping gl HWG Water Piping 1 Using at least 5 8 16mm O D copper route and install the water piping valves and air vent as shown in Figures 15 to 18 The air vent MUST be at the high point of the HWG water piping 2 Insulate all HWG water piping with no less than 3 8 10mm wall closed cell insulation 3 Open both shut off valves and make sure the tank drain valve is closed Water Tank Refill 1 Open the cold water supp
30. element to 100 110 38 43 Shut off Valve Powered Water Heater Insulated water lines 5 8 OD 50 ft 15m tank connection fitting eliminates the need to tie into the hot water tank cold water piping but is more susceptible to scaling The optional concentric fitting part 569619804 is available from your equipment supplier and should be installed as shown in Figure 17 for applications with low scaling potential or where a water softener is used Consult Table 3 for scaling potential tests It is always advisable to use water softening equipment on domestic water systems to reduce the scaling potential and lengthen equipment life In extreme water conditions it may be necessary to avoid the use of the HWG option since the potential cost of frequent maintenance may offset or exceed any savings R 410 systems inherently have a lower hot gas temperature than R 22 systems because the equipment is more efficient i e less waste heat is available It is possible that energy could be transferred from the water heater to the hot gas line instead of from the hot gas line to the water heater during certain times of the year To prevent this from occuring a temperature switch will deactivate the pump at those conditions that typically occur in the cooling mode with entering water temperatures of less than 50 F 10 C Installation The HWG high limit temperature switch is set at 125
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32. locked into 1st stage operation only If PSC fan is used unit must be locked into either 1st or 2nd stage An ECM fan is required for two stage operation and for ARI ratings Size air handler for Full Load if operating in two stage mode When selecting an air handler based upon the above conditions choose entering WB temperature of 67 F Use evaporator temperature CFM and capacity requirements as listed above The air handler capacity must be at least at the minimum capacity shown in the table in order for the ARI rating condition to be valid See Figure 1 for an example selection Indoor Coil Selection R 22 Units Geothermal split system heat pumps with R 22 refrigerant are rated in the ARI directory with a generic indoor coil match and PSC fan Selection of air handlers that attain the published ARI ratings must meet or exceed the specifications listed in Table 2 A TXV is required Cap tubes and fixed orifices are not acceptable Capacity MBtuh Table 2 R 22 Air Handler Characteristics SES aw Temp F CFM 185 13 47 80 255 293 49 100 315 362 48 1 370 425 45 1 422 495 4 160 500 575 Nominal tons are at ARI ISO 13256 1 GLHP conditions When selecting an air handler based upon the above conditions choose entering WB temperature of 67 F Use evaporator temperature CFM and capacity requirements as listed above The air handler cap
33. minutes of run time See tables 13a to 14 for superheat and sub cooling values Superheat is measured using suction temperature and pressure at the compressor suction line Subcooling should be measured using the liquid line temperature immediately outside the compressor section cabinet and either the liquid line service valve pressure or the compressor discharge pressure Note that different values from tables 13a to 14 will be obtained due to the pressure losses through the condenser heat exchanger Adding refrigerant will increase sub cooling while superheat should remain fairly constant allowing for a slight amount of hunting in TXV systems This increase in subcooling will require 5 minutes or so of operation before it should be measured After values are measured compare to the chart and go to FINAL EVALUATION PARTIAL CHARGE METHOD Open service valve fully counterclockwise and then turn back in one half turn to open service port Add vaporized Gas into the suction side of the compressor until the pressure in the system reaches approximately 60 70 psig R 22 systems or 100 120 psig R 410A systems Never add liquid refrigerant into the suction side of a compressor Start the unit in heating and add gas to the suction port at a rate not to exceed five pounds 2 27 kg per minute Keep adding refrigerant until the complete charge has been entered Superheat is measured using suction temperature and pressure at the compressor suctio
34. no connection DIP Switches Note In the following field configuration options DIP Switches should only be changed when power is removed from the CXM control DIP switch 1 Unit Performance Sentinel Disable provides field selection to disable the UPS feature On Enabled Off Disabled DIP switch 2 Stage 2 Selection provides selection of whether compressor has an on delay If set to stage 2 the compressor will have a 3 second delay before energizing Also if set for stage 2 the alarm relay will NOT cycle during test mode On Stage 1 Off Stage 2 DIP switch 3 Not Used DIP switch 4 DDC Output at EH2 provides selection for DDC operation If set to DDC Output at EH2 the EH2 terminal will continuously output the last fault code of the controller If set to EH2 normal EH2 will operate as standard electric heat output On EH2 Normal Off DDC Output at EH2 NOTE Some CXM controls only have a 2 position DIP switch package If this is the case this option can be selected by clipping the jumper which is in position 4 of SW1 Jumper not clipped EH2 Normal Jumper clipped DDC Output at EH2 DIP switch 5 Factory Setting Normal position is On Do not change selection unless instructed to do so by the factory Table 9a CXM LED And Alarm Relay Operations Description of Operation _ LED Normal Mode On Normal Mode with UPS Warning closed 5 sec Open 25 sec
35. or in brackish water a cupro nickel heat exchanger is recommended In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be present an open loop system is not recommended Heat exchanger coils may over time lose heat exchange capabilities due to build up of mineral deposits Heat exchangers must only be serviced by a qualified technician as acid and special pumping equipment is required Desuperheater coils can likewise become scaled and possibly plugged In areas with extremely hard water the owner should be informed that the heat exchanger may require occasional acid flushing In some cases the desuperheater option should not be recommended due to hard water conditions and additional maintenance required Water Quality Standards Table 3 should be consulted for water quality requirements Scaling potential should be assessed using the pH Calcium hardness method If the pH 7 5 and the Calcium hardness is less than 100 ppm scaling potential is low If this method yields numbers out of range of those listed the Ryznar Stability and Langelier Saturation indecies should be calculated Use the appropriate scaling surface temperature for the application 150 F 66 for direct use well water open loop and DHW desuperheater 90 F 32 F for indirect use monitoring plan should be implemented in these probable scaling situations Other water quality issues such as iron fouli
36. that eliminates the need to tie into the heat pump refrigerant circuit in the field The control circuit and pump are also built in for residential equipment Figure 15 shows a typical example of HWG water piping connections on a unit with built in pump This piping layout minimizes scaling potential The outdoor compressor section utilizes an add on HWG module that ties into the hot gas line of the compressor section The HWG module is remotely mounted near the water heater and includes a water to refrigerant heat exchanger pump and controls Figure 18 is a typical example of a remote module HWG system Electric water heaters are recommended If a gas propane or oil water heater is used a second preheat tank must be installed Figure 16 If the electric water heater has only a single center element the dual tank System is recommended to insure a usable entering water temperature for the HWG Typically a single tank of at least 52 gallons 235 liters is used to limit installation costs and space However a dual tank as shown in Figure 16 is the most efficient system providing the maximum storage and temperate source water to the HWG Using a concentric or coaxial hot water Figure 15 Typical HWG Installation Indoor Compressor Section Cold Inlet Hot Outlet Cold Suppl to home Shut off Valve with Waste Vent at high point Upper element to 120 130 F MI 49 54 C Lower
37. the joint HAND TIGHTEN ONLY DO NOT OVERTIGHTEN Figure 4 Water Connections Indoor Compressor Section Hand Tighten REDEE Only Swivel Nut Do Not Overtighten Stainless steel MMMM NN RASS snap ring lt lt Gasket Brass Adaptor Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 2007D INSTALLATION Figure 5 Water Connections Outdoor Compressor Section Internal Flow Controller Mounting Outdoor Compressor Section Only The Flow Controller can be mounted in the outdoor compressor section directly inside the cabinet as shown in Figure 5 Remove the water legs from the outdoor unit at the union fittings Attach the 1 x o ring fittings to the removed water legs Carefully attached the Flow Controller to the loop piping and mount to the outdoor unit using the mounting lugs attached to the unit Insert the water legs into the Flow Controller using the o ring fittings Re connect the water leg unions NOTICE Opening in the bottom of the unit for loop piping must be sealed to prevent rodents from getting into the cabinet and damaging control wiring Spray type foam may be used to seal the opening s Figure 6 Connector e 4 amp 3 S F I 22 x w Mount Flow Controller on studs provided Wire pump power using provided wires for L1 and L2 GROUND LOOP HEAT PU
38. the thermostat mode switch in the HEAT position b Slowly raise the thermostat to a higher temperature until the compressor activates c Check for warm air delivery within a few minutes after the unit has begun to operate d Referto Table 11 Check the temperature of both entering and leaving water If temperature is within range proceed with the test If temperature is outside of the operating range check refrigerant pressures and compare to Tables 14 and 15 Verify correct water flow by comparing unit pressure drop across the heat exchanger versus the data in Tables 12a through 12b Heat of extraction HE can be calculated and compared to submittal data capacity pages The formula for HE for systems with water is as follows TD x GPM x 500 where TD is the temperature difference between the entering and leaving water and GPM is the flow rate in U S GPM determined by comparing the pressure drop across the heat exchanger to Tables 12a through 12b e Check air temperature rise across the air coil when compressor is operating Air temperature rise should be between 20 F and 30 F 11 C and 17 f Check for vibration noise and water leaks 7 If unit fails to operate perform troubleshooting analysis see troubleshooting section If the check described fails to reveal the problem and the unit still does not operate contact a trained service technician to insure proper diagnosis and repair of the equipment
39. vary the airflow supply air temperatures may not be acceptable if the compressor is allowed to change stages when used with a PSC fan motor Table 1a GT PX 50705 Geothermal Split System Air Handler Matches for ARI Ratings Compressor Section Air Handler Bees FV4 or FE4 Refrigerant Metering Device Air Coil Type Rows Fins in Face Area sq ft Cabinet Configuration ECM Settings for ARI Ratings FV4 Fan Coil AC HP size 036 System Type Comfort AC HP Adjust Nom AC HP size 036 System Type HP Effic AC HP CFM Adjust High R 410A TXV required Upflow Downflow Horizontal Multipoise AC HP size 048 System Type Comfort AC HP CFM Adjust High AC HP size 060 System Type Comfort AC HP CFM Adjust High Fan Motor Type HP ECM 1 2 ECM 1 2 ECM 3 4 ECM 3 4 Residential Split 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 20070 EQUIPMENT SELECTION Table 1b Selection of Coils other than Above Models for Geothermal Split Systems Add on CK5P FX4 PSC combination 530 880 700 026 Part Load 50 026 Full Load ss 192 224 ATW 088 ae 242 282 MATOS 70 252 292 ATW 08 2 ATI O36 Nominal tons are at ARI ISO 13256 1 GLHP conditions Two stage units may be operated in single stage mode if desired where smaller capacity is required For example a model 026 may be used as a 1 1 2 ton unit if
40. 0 2 ppm avoid use of copper and copper nickel piping or HX s Hydrogen Sulfide 25 e Rotten egg smell appears at 0 5 ppm level Copper alloy bronze or brass cast components are OK to lt 0 5 ppm Minimize steel pipe below 7 and no open tanks with pH lt 8 Ammonia ion as hydroxide chloride nitrate and sulfate compounds lt 0 5 ppm Maximum Allowable at maximum water temperature 50 F 10 C 75 F 24 C 100 F 38 C lt 20ppm lt 150 ppm lt 400 ppm lt 1000 ppm Titanium gt 1000 ppm Erosion and Clogging Maximum Chloride Levels lt 10 ppm of particles and a maximum 10 ppm 1 ppm sandfree for reinjection of particlesand a maximum Particulate Size and velocity of 6 fps 1 8 m s velocity of 6 fps 1 8 m s Filtered for maximum 800 micron 800mm Erosion Filtered for maximum 20 mesh size Any particulate that is not removed can potential 800 micron 800mm clog p y 20 mesh size Notes Rev 11 17 060 Closed Recirculating system is identified by a closed pressurized piping system Recirculating open wells should observe the open recirculating design considerations NR Application not recommended Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 20070 REFRIGERATION INSTALLATION CAUTION A CAUTION R 410A systems operate at higher pressures than R 22 systems Be certain that service equipment gauges tools etc is rated for R 410A S
41. 1531 1 3009 ON SGOW 1531 SI N3ldv 935015 840 14 MOIS NMOGLNHS 35v110A eor O 1105001 LYWd eee CIWNOLIOND NON ST XO 285 52 340 53 455012 31242 SNINHVM Sd M IAOW IWWHON 30 300W TWWHON WAV TV 031 NOLLV233dO 40 NOILdIN2S30 S3d02 LINVA M3TIOMINOO WX MO 244 bU dnd ML E 7 3LON L MOSS3HdHO 4 ALON 335 1 l 1 09 0 2 802 5 LINN NOY 31vN34dO Ol LINN 39V S OML 304 QION310S 01 38 LSNW ZA 6 TWNYALNI NOILVH3N39 YILYM LOH NI AINO SMH 8 NMOHS SV S4JOGNVLS 401 10N1NO 01 SM3N2S SJJOCNVIS VIA AMNVONO23S L ZV 1 38 LOVLNOD AYG ONY YAWN 102 LOWLNOD WV TY ANG 04 NMCHS TYNSIS WYVIV AYZ 9 1239000996 39V110A 4744105 4319349 40 OL ONILVY 39 1 10 ANY 55770 38 LSNW 9NIMIM LVIS LINN FHL 01 403 SNOILONYLSN NOLLVTTVISN LVLSOWYSHL OL 93333 LVLSOWYSHL 21412345 YO4 NOILVWYOINI NO LVTIVISNI Y23H EMP LNI 8 011105 3Z33J LLNV ONISN N3
42. 202 per ft for 1 2 1 19 per cm of lineset used TFactory charge is preset for 25 7 6 meters lineset Residential Split 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 2007D REFRIGERATION INSTALLATION Figure 10 Braze Instructions Fully Insulated lt Suction Line OJO d Fully Insulated Liquid Line Nitrogen Braze Replace Caps after adjusting service valves Rev 05 31 00 for gauges ER Replace caps IT after adjusting service valves Service ports for attaching refrigerant gauges Service Port Closed Position Full Out CCW Full Out 1 2 turn CW CW Full In Description System Operation Position Service Position Shipping Position Open Installing the Indoor Coil and Lineset Figure 11 shows the installation of the lineset and TXV to a typical indoor coil An indoor coil or air handler fan coil with a TXV is preferred Coils with cap tubes may not be used If coil includes removable fixed orifice the orifice must be removed and a TXV must be installed as shown in Figure 11 Fasten the copper line set to the coil Nitrogen should be circulated through the system at 2 3 psi 13 8 20 7 kPa to prevent oxidation inside the refrigerant tubing Use a low silver phos copper braze alloy on all brazed connections Figure 11 Air Coil Connection Bulb TXV IN
43. 5 13 5 8 7 10 7 5 9 7 9 319 339 7 12 5 10 329 349 7 12 5 10 336 356 7 12 5 10 365 385 7 12 5 10 374 394 7 12 5 10 388 408 7 12 5 10 19 6 21 6 15 17 10 3 12 3 Operation Not Recommended Air Temp Rise F DB 18 24 19 25 20 26 25 31 26 32 26 32 31 38 32 39 32 39 37 45 38 46 38 46 Air Temp Rise F DB 17 23 18 24 19 25 23 29 24 30 24 30 28 35 29 36 30 37 36 44 37 45 39 47 Air Temp Rise F DB Residential Split 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 2007D Entering Water Temp F GPM ton Suction Pressure PSIG 117 127 116 126 115 125 126 136 124 134 123 133 130 140 129 139 128 138 138 1438 132 142 132 142 138 148 137 147 136 146 UNIT OPERATING CONDITIONS Table 14d Size 064 Two Stage R 410A Typical Unit Operating Pressures and Temperatures Full Load Cooling without HWG active Discharge Pressure PSIG 160 180 133 153 125 145 228 248 212 232 195 215 305 325 286 306 266 286 398 418 376 396 354 374 505 525 483 503 459 479 Sub cooling Super heat 16 21 17 22 18 23 8 13 6 11 5 10 8 13 11 16 14 19 8 13 Water Temp Rise F 17 5 19 5 11 9 13 9 6 3 8 3 19 8 21 8 14 2 16 2 8 5 10 5 20 3 22 3 14 8 16 8 9 3 11 3 19 4 21 4 14 1 16 1 8 8 10 8 18 3 20 3 13 3 15 3 8 3 10 3 Air Temp Drop F DB Suction Pressure PSIG 95 105 100 110 105 115 128 138 133 143 139 149
44. 6 9 49 0 65 0 6 1 113 71 35 3 42 9 20 6 28 3 04 cm 56 9 49 0 65 0 13 7 853 42 9 20 6 28 3 ESESESESES 56 9 49 0 65 0 A 12 7 85 3 42 9 20 6 28 3 in 224 193 256 139 169 __ cm 56 9 49 0 65 0 13 7 35 3 42 9 78 3 8 20 6 28 3 in 254 213 306 159 189 of 124 cm 64 5 54 1 77 7 13 7 40 4 48 0 UE 3 8 23 2 30 8 64 5 54 1 77 7 11 13 7 40 4 48 0 23 2 30 8 in 254 213 306 159 189 e1 121 APAE Ae pos pe Rev 08 10 05D 3 4 HV Knockout 1 2 LV Knockout GT S Split 38WQS Series 22 33 EN __155 9 83 8cm 26 66 0cm dee T Em Residential Split 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 2007D EQUIPMENT SELECTION The installation of geothermal heat pump units and all associated components parts and accessories which make up the installation shall be in accordance with the regulations of ALL authorities having jurisdiction and MUST conform to all applicable codes It is the responsibility of the installing contractor to determine and comply with ALL applicable codes and regulations General Proper indoor coil selection is critical to system efficiency Using an older model coi
45. CXM is non functional Alarm Relay Off Fault Retry Slow Flash Fast Flash Open Closed after 15 minutes Over Under Voltage Shutdown Slow Flash Test Mode No fault in memory Flashing Code 1 Cycling Code 1 Test Mode HP Fault in memory Flashing Code 2 Cycling Code 2 Test Mode LP Fault in memory Flashing Code Test Mode FP1 Fault in memory Flashing Code 4 Cycling Code 3 Cycling Code 4 Cycling Code 5 Test Mode FP2 Fault in memory Flashing Code 5 Cycling Code 6 Test Mode CO Fault in memory Flashing Code 6 Test Mode Over Under Flashing Code 7 shutdown in memory Flashing Code 8 Test Mode Swapped Thermistor Flashing Code 9 Cycling Code 7 Test Mode UPS in memory Cycling Code 8 Cycling Code 9 Slow Flash 1 flash every 2 seconds Fast Flash 2 flashes every 1 second Flash code 2 2 quick flashes 10 second pause 2 quick flashes 10 second pause etc On pulse 1 3 second off pulse 1 3 second Residential Split 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 2007D CXM CONTROLS Safety Features CXM Control The safety features below are provided to protect the compressor heat exchangers wiring and other components from damage caused by operation outside of design conditions Anti short cycle protection The control features a 5 minute anti short cycle protection for the compressor Note The 5 minute anti short cycle also occurs at power up Ran
46. DB 19 25 20 26 20 26 19 25 20 26 20 26 19 25 20 26 20 26 18 24 18 24 18 24 18 24 18 24 18 24 Air Temp Drop F DB Suction Pressure PSIG 77 87 79 89 82 92 107 117 111 121 115 125 139 149 145 155 152 162 177 187 181 191 186 196 Suction Pressure PSIG 71 81 75 85 78 88 103 113 107 117 112 122 134 144 140 150 146 156 172 182 184 194 196 206 Suction Pressure PSIG 123 133 130 140 137 147 167 177 177 187 187 197 Full Load Heating without HWG active Discharge Super Sub Water Temp Pressure heat cooling Drop F PSIG 4 9 278 298 10 15 280 300 10 15 282 302 10 15 314 334 315 335 317 337 13 18 13 18 13 18 350 370 352 372 354 374 15 20 15 20 15 20 11 3 13 3 8 5 10 5 5 8 7 8 17 22 17 22 17 22 14 4 16 4 10 8 12 8 7 1 9 1 392 412 397 417 402 422 Full Load Heating without HWG active Discharge Super Sub Water Temp Pressure bi PSIG heat cooling Drop F 263 283 5 10 267 287 5 10 270 290 5 10 292 312 6 11 296 316 6 11 301 321 6 11 11 5 13 5 8 6 10 6 5 7 7 7 14 5 16 5 11 1 13 1 7 7 9 7 20 5 22 5 15 17 10 12 322 342 7 12 328 358 334 354 360 380 369 389 378 398 Full Load Heating without HWG active Discharge Super Sub Pressure heat cooling PSIG 261 281 8 13 5 10 264 284 8 13 5 10 267 287 8 13 5 10 289 309 7 12 5 10 295 315 7 12 5 10 301 321 7 12 5 10 Water Temp Drop F 11
47. HM NOILI3LONd 323344 S3dIAONd N3ISIHNSH dd NMOHS SV X 039112 SQV31 OJA OL 244 54 31 OIA INIM 2 NOISNVaX3 9 3010811519 N33MI38 34402 NO NOILIAS NI LINN G3ddIHS YOLSIWNIHL 243 TIVISN 78 HOLIMS 4007 OIA 1304 2 HOLIMS 410 9NIMIM 244 lt 7109 3002 1V201 DSN LSAW Ol 9NIMIM TIY 2 S2018 TWN ATIVNN3INI 934931044 ATIVWYSHL 905534480271 N3wod 5110 91720 90 one ON alva ISL IMS 284 184 HOLIMS 34055244 304 2 20 5507 HOLIMS 0123738 4 738742112 ivis Vno 9NLLV3H 7 2 4 23 ldd 28d 1 7 i3 HOLIMS dH3l 39YVH SIA 510 ALYSNIONOJ MOSNSG N012V1NO2 NOSS3HdKD2 WaVTY LOVLNOD 9 310N 335 TVNIWHSL WoldAL 310N 335 eme AJNO SLINN 39 15 OML QION310S 89715 0 0235 40553444092 j 1 301 1n0AV XOg 10841 02 8 ILON 33S perdiet 2 819 1 00 7102 YOLIVINOD AVIY O N S12V1N02 1 894 39V130A 20 49078 1140
48. MP APPLICATIONS A CAUTION A CAUTION The following instructions represent industry accepted installation practices for closed loop earth coupled heat pump systems Instructions are provided to assist the contractor in installing trouble free ground loops These instructions are recommendations only State provincial and local codes MUST be followed and installation MUST conform to ALL applicable codes It is the responsibility of the installing contractor to determine and comply with ALL applicable codes and regulations Pre Installation Prior to installation locate and mark all existing underground utilities piping etc Install loops for new construction before sidewalks patios driveways and other construction has begun During construction accurately mark all ground loop piping on the plot plan as an aid in avoiding potential future damage to the installation Piping Installation The typical closed loop ground source system is shown in Figures 7 and 8 All earth loop piping materials should be limited to polyethylene fusion only for in ground sections of the loop Galvanized or steel fittings should not be used at any time due to their tendency to corrode plastic to metal threaded fittings should be avoided due to their potential to leak in earth coupled applications A flanged fitting should be substituted P T plugs should be used so that flow can be measured using the pressure drop of the unit heat exchanger
49. OLTAGE WIRING Thermostat Connections Figure 22c 38WQS Low Voltage Field Wiring The thermostat should be wired directly to the CXM board Figures 22a through 22c show low voltage wiring Note that the air handler or furnace transformer will be used CXM Control to power the CXM board in the compressor section See Electrical Thermostat for specific terminal connections Figure 22a 50YDS Low Voltage Field Wiring Low Voltage Connector ermostat Connection See Thermostat section for Wiring Details Low voltage field wiring Low Water Temperature Cutout Selection The CXM control allows the field selection of low water or water antifreeze solution temperature limit by clipping jumper JW3 which changes the sensing temperature associated with thermistor FP1 Note that the FP1 Figure 22b 50YCS Low Voltage Field Wiring thermistor is located on the refrigerant line between the coaxial heat exchanger and expansion device TXV Therefore FP1 is sensing refrigerant temperature not water temperature which is a better indication of how water flow rate temperature is affecting the refrigeration circuit m Circ Brkr The factory setting for FP1 is for systems using water 30 F 1 1 C refrigerant temperature In low water temperature extended range applications with antifreeze most ground loops jumper JW3 should be clipped as
50. ON VOLTAGE 3 208V 230V 1PH 60Hz HEAT EXCHANGER OPTIONS CONTROL C COPPER WATER COIL YDS D COPPER WATER COIL W HOT WATER GENERATOR YCS N CUPRO NICKEL WATER COIL P CUPRO NICKEL WATER COIL W HOT WATER GENERATOR NOTE Some options configurations not availaible on all series Please consult Engineering Guides for model specific options Rev 08 15 05D NOTE Above model nomenclature is a general reference Consult individual specification catalogs for detailed information MODEL NOMENCLATURE FOR OUTDOOR SPLIT SERIES 123 4 024 6 7 12 WOSIl02 411557 113 01 Prefix Packaging 1 Single Pack Domestic Series WQS Extended Range Ultra High Revision Level Efficiency Residential Outdoor Split 1 Current Revision Unit Size Voltage 018 024 030 036 042 048 060 3 208 230 60 1 Standard Heat Exchanger Options SS Standard Cupro Nickel Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 20070 SAFETY Safety Warnings cautions and notices appear throughout this manual Read these items carefully before attempting any installation service or troubleshooting of the equipment DANGER Indicates an immediate hazardous situation which if not avoided will result in death or serious injury DANGER labels on unit access panels must be observed WARNING Indicates a potentially hazardous situation which if not avoided could resul
51. See Insufficient Capacity _______________ Capacity High humidity X Too high of air flow Check fan motor speed selection and chart _____ X Unit oversized Recheck loads amp sizing check sensible clg load and heat pump capacity Residential Split 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 2007D Air Temperature out of range TROUBLESHOOTING FORM Customer Antifreeze Model Serial Loop type Complaint HEATING CYCLE ANALYSIS Refrigerant MNNNNS oe R410A H F R22 XM SN SSSI COOLING HEATING R407C EXPANSION NN VALVE VALVE Look up pressure drop in or spec catalog to determine flow rate LIQUID LINE oF oF PSI PSI a WATERIN WATER OUT lt COOLING CYCLE ANALYSIS E AIR HANDLE RS ECTIO ES SORS ECTION UM Fp OIL WMNNM COOLING EXPANSION RUNE VALVE HEATING EXPANSION VALVE F Look up pressure drop in or spec catalog to 1 QUIDLINE PSI _____ 5 determine flow rate WATER IN WATER QUI Cooling expansion valve meters in the cooling mode and bypasses the heating mode Heating expansion valve meters in the hea
52. Split Products GT PX Split BOYDS Series GT G Split BOYCS Series e GT S Split 38WQS Series D ejas Indoor and Outdoor Split _ Geothermal Heat Pumps Installation Operation amp Maintenance Instructions 97B0048N01 Revision 28 June 2007D Table of Contents Model Nomenclature Power Wiring 30 Safety Electrical Low Voltage Wiring Storage Low Water Temperature Cutout Selection 31 Pre Installation Water Valve Wiring 32 Physical Data Thermostat Wiring 33 Unit Dimensions Electrical Wiring Schematics 34 36 Equipment Selection CXM Controls 37 40 Air Coil Match ups CXM Safety Control Reset 38 Air Handler Selection Unit Start Up and Operating Conditions 41 42 Water Connections Unit and System Checkout Procedure 42 Ground Loop Applications Unit Start Up Procedure 42 43 Open Loop Ground Water Systems Coax Pressure Drop Table 44 Water Quality Standards Operating Pressures 45 46 Refrigeration Installation Preventive Maintenance 47 Lineset Information Troubleshooting 48 49 Internal Hot Water Generator Functional amp Performance Troubleshooting 50 51 Hot Water Generator Module Refrigerant Circuit Diagram 52 Electrical Line Voltage Warranty 53 MODEL NOMENCLATURE GENERAL OVERVIEW FOR INDOOR SPLIT SERIES 8 SOY UNIT TYPE T PACKAGING YDS INDOOR TWO STAGE PURON 1 SINGLE PACK DOMESTIC SPLIT SYSTEM CONDENSING UNIT YCS INDOOR SPLIT SYSTEM CONDENSING UNIT REVISION LEVEL 0 CURRENT REVISI
53. UST conform to all applicable codes It is the responsibility of the installing contractor to determine and comply with ALL applicable codes and regulations Removing Existing Condensing Unit Where Applicable 1 Pump down condensing unit Close the liquid line service valve of existing condensing unit and start compressor to pump refrigerant back into compressor section Then close suction service valve while compressor is still running to trap refrigerant in outdoor section Immediately kill power to the condensing unit 2 Disconnect power and low voltage and remove old condensing unit Cut or unbraze line set from unit Remove condensing unit 3 If condensing unit is not operational or will not pump down refrigerant should be recovered using appropriate equipment 4 Replace line set especially if upgrading system from R 22 to R 410A refrigerant If line set cannot be replaced it must be thoroughly flushed before installing new compressor section R 410A compressors use POE oil instead of mineral oil R 22 systems Mineral oil is not compatible with POE oil and could cause system damage if not completely flushed from the line set Indoor Compressor Section Location Both indoor and outdoor versions of the geothermal split system compressor section are available Indoor version is not designed for outdoor installation Locate the unit in an INDOOR area that allows enough space for service personnel to perform typical ma
54. acity must be at least at the minimum capacity shown in the table in order for the ARI rating condition to be valid See Figure 1 for an example selection 50 47 49 48 45 46 5 Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 20070 EQUIPMENT SELECTION Air Handler Selection Example Figure 1 shows a typical peformance table for a heat pump air handler Suppose the evaporator temperature required is 50 F the capacity required is 35 000 Btuh and the airflow required is 1 200 CFM Each evaporator temperature listed in the table shows three wet bulb temperatures As recommended in the table notes above select the 67 F WB column At 1 200 the model 003 capacity is 36 MBtuh which is higher than the minimum capacity required of 35 000 Btuh In this example model 003 would be the appropriate match Figure 1 Selecting Air Handler COIL REFRIGERANT TEMPERATURE 5 55 UNIT aa Evaporator Air Entering Wet Bulb Temperature F SIZE 72 67 62 72 67 62 72 67 62 72 Gt 62 72 67 62 59 48 53 42 32 46 35 24 so 27 20 30 148 16 3 2 a ooo es 56 oo 57 a1 20 a5 32 25 a5 22 20 o2 wT 3 T 123 2 2 a 42 32 38 29 32 33 26 28 29 22
55. actory Charge R410A oz kg 90 2 55 104 2 95 126 3 57 168 4 76 Water Connection Size IPT in HWG Connection Size All units have spring compressor mountings TXV expansion devices and 1 2 12 2mm amp 3 4 19 1mm electrical knockouts GT G Split 507 5 Series Modei o4 036 042 oso Compressor 1 Each Scroll Water Connection Size IPT in HWG Connection Size IPT in Line Set Connection Size We Packages b I All units have spring compressor mountings expansion devices and 1 2 12 2mm amp 3 4 19 1mm electrical knockouts GT S Split 38WQS Series 54 o 02 Factory R22 GZ O Water Connection Size eer Wight Packages b T All units have spring compressor mountings TXV expansion devices weather resistant cabinet and 1 2 12 2mm amp 3 4 19 1mm electrical knockouts Hot Water Generator with factory installed hot gas service ports Residential Split 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 2007D DIMENSIONS GT PX SPLIT 50705 SERIES GT PX Two Stage Split BOYDS Series Overall Cabinet Water Connections Refrigerant Connection Electrical Knockouts n uc In Out Water Liquid EC CS ER EE COR ES TCR EHE ES om 569 490 650 41 sa 279 353 429 185 130 155 212 36 Fin
56. agnostic ease at the thermostat the alarm relay will also cycle during test mode The alarm relay will cycle on and off similar to the status LED to indicate a code representing the last fault at the thermostat Test mode can be exited by shorting the test terminals for 3 seconds Retry Mode If the control is attempting a retry of a fault the status LED will slow flash slow flash one flash every 2 seconds to indicate the control is in the process of retrying Field Configuration Options Note In the following field configuration options jumper wires should be clipped ONLY when power is removed from the CXM control Water coil low temperature limit setting Jumper 3 JW3 FP1 Low Temp provides field selection of temperature limit setting for FP1 of 30 F 10 F 1 F or 12 C refrigerant temperature Not Clipped 30 F 1 C Clipped 10 F 12 C Air coil low temperature limit setting Jumper 2 JW2 FP2 Low Temp provides field selection of temperature limit setting for FP2 of 30 F or 10 F 1 F or 12 C refrigerant temperature Note This jumper should only be clipped under extenuating circumstances as recommended by the factory Not Clipped 30 F 1 C Clipped 10 F 12 C Alarm relay setting Jumper 1 JW1 AL2 Dry provides field selection of the alarm relay terminal AL2 to be jumpered to 24VAC or to be a dry contact no connection Not Clipped AL2 connected to Clipped AL2 dry contact
57. al for future servicing R22 units only 6 Provide access to water valves and fittings and Screwdriver access to the unit side panels and all electrical connections Outdoor Compressor Section Loacation Locate the unit in an outdoor area that allows easy loop and lineset access and also has enough space for service personnel to perform typical maintenance or repairs The outdoor compressor section is usually installed on a condensor pad directly outside the lineset access into the building The service valve side can be located toward the building keeping the loop access end away from the building Conform to the following guidelines when selecting unit location 1 Provide adequate access for loop trench excavation 2 Locate unit directly outside lineset penetration if possible Utilize existing condensor pad where possible 3 Provide access for servicing and maintenance Outdoor compressor section may be mounted on a vibration isolation pad with loop access hole as shown in Figure 3 When mounting on an existing concrete condenser pad 3 76mm holes should be bored through the pad to accomodate the pipe 1 1 4 32mm and insulation 1 2 18mm wall thickness Figure 3 illustrates location and dimensions of the holes required Air Handler Installation This manual specifically addresses the compressor section of the system Air handler location and installation should be according to the instructions provided wi
58. copper conductor and Minimum Circuit Ampacity Table 8b GT G Split BOYCS Series Electrical Data Compressor External Min Wire i Circuit pn FLA Amps 12 2 67 0 0 40 4 0 16 6 19 7 94 28 7 4 0 18 5 73 0 0 40 17 9 21 3 87 26 5 95 0 0 40 20 9 25 0 74 22 6 109 0 0 40 227 27 3 67 20 7 148 0 0 40 29 4 35 7 82 25 2 Rated Voltage of 208 230 60 1 Min Max Voltage of 197 254 HACR circuit breaker in USA only All fuses Class RK 5 Wire length based on one way measurement with 2 voltage drop Wire size based on 60 C copper conductor and Minimum Circuit Ampacity Table 8c GT S Split 38WQS Series Electrical Data Compressor Min Max Circuit Wire Ft LRA Qty Amps m 38 0 1 13 3 87 26 6 56 0 17 4 106 32 5 67 0 19 8 93 28 6 73 0 21 4 86 26 4 95 0 i 25 2 73 22 4 109 0 i 274 67 20 6 148 0 j 1 i 35 9 82 25 1 Rated Voltage of 208 230 60 1 Min Max Voltage of 197 254 HACR circuit breaker in USA only All fuses Class RK 5 Wire length based on one way measurement with 296 voltage drop Wire size based on 60 copper conductor and Minimum Circuit Ampacity Residential Split 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 2007D ELECTRICAL POWER WIRING Electrical Line Voltage All field installed wiring including electrical ground must comply with the Na
59. d should be used with the ARI matched air handler EXAMPLE R22 model 048 with 40 feet 12 meters of installed liquid line 3 8 O D The basic charge of model 048 is 115 oz 3 26 kg The 40 ft 12 meter 3 8 line set requires 24 oz 0 72 kg 40 ft x 0 6 2 24 oz 1200cm x 0 6g cm 7209 Total charge 115 24 139 oz 3 26 0 72 3 98 kg The compressor section is shipped from the factory with 130 oz 3 69 kg of refrigerant for 25 ft 7 6m lineset so the amount to be added is 9 oz 0 29 kg total charge shipped charge charge to be added Table 6b R 410A Charging Values A NOTICE A NOTICE Use tables 14a to 15 for superheat subcooling values These tables use discharge pressure converted to saturation temperature and liquid line temperature for subcooling calculations If using liquid line pressure subtract 3 F from the table values Residential Split 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 2007D REFRIGERATION INSTALLATION Turn service valves full out CCW see Table 5 and then turn back in one half turn to open service ports Add the required refrigerant so that the total charge calculated for the unit and line set is now in the system Open the Service valve fully counter clockwise so that the stem will backseat and prevent leakage through the schrader port while it is not in use Start unit in the heating mode and measure superheat and subcooling values after 5
60. dom start The control features a random start upon power up of 5 80 seconds Fault Retry In Fault Retry mode the Status LED begins slowly flashing to signal that the control is trying to recover from a fault input The control will stage off the outputs and then again to satisfy the thermostat input call Once the thermostat input call is satisfied the control will continue on as if no fault occurred If 3 consecutive faults occur without satisfying the thermostat input call the control will go into lockout mode The last fault causing the lockout will be stored in memory and can be viewed by going into test mode Note FP1 FP2 faults are factory set at only one try Lockout In lockout mode the status LED will begin fast flashing The compressor relay is turned off immediately Lockout mode can be soft reset by turning off the thermostat or satisfying the call A soft reset keeps the fault in memory but resets the control A hard reset disconnecting power to the control resets the control and erases fault memory Lockout with emergency heat While in lockout mode if W becomes active CXM emergency heat mode will occur High pressure switch When the high pressure switch opens due to high refrigerant pressures the compressor relay is de energized immediately since the high pressure switch is in series with the compressor contactor coil The high pressure fault recognition is immediate does not delay for 30 con
61. e approximately 5 10 F 3 6 C 6 Allow the unit to operate for 20 to 30 minutes to insure that it is functioning properly Figure 18 HWG Installation shown with optional concentric coaxial fitting part 327869619804 not included with unit Outdoor Compressor perdon gu Outlet Insulated line set with Insulated water UN UV Paint lines A Heater Insulated lineset enters structure Waste Vent Coupling Coaxial Fitting 2 Add On Hot Water with internal pump gt Residential Split 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 20070 HWG MODULE REFRIGERATION INSTALLATION OUTDOOR COMPRESSOR SECTION ONLY General Information The HWG Module consists of an all copper vented double wall heat exchanger and a water cooled water circulating pump The pump is controlled by the use of one or more limit switches Power for the pump is provided from either the compressor contactor of the outdoor section of the heat pump or it may come from a remote power source if the appropriate controls are used Location Mounting The HWG module should be mounted as close to the heat pump outdoor section as possible in order to minimize the length of refrigerant run Indoor mounting is preferred where practical to reduce the likelihood of freezing ambient temperature It is recommended that the HWG module be mounted above the system compressor in order to promo
62. e lineset to 500 microns through the hot gas valves in the outdoor unit Open the valves up fully CCW looking up from cap end Check the lineset for leaks Pinch the bypass tubing as shown in Figure 19 being careful not to damage the tubing Verify that lineset tubing is completely insulated with a minimum 1 2 thick closed cell and painted to prevent deterioration of the insulation due to ultra violet light and weather Make the connections with high temperature solder or brazing rod The recommended line size is dependent on the one way distance between the Heat Recovery Unit and the compressor and the size of the system Use the Table 7 as a guideline Table 7 HWG Module Lineset Sizing Line Set Size peer 2 Ton Up to 16 ft Up to 30 ft N A 4 9m 9 1m 3 Ton Up to 9 ft Up to 25 ft Up to 30 ft 2 7m 7 6m 9 1 m 4 Ton Up to 5 ft Up to 13 ft Up to 30 ft 1 5m 4 0m 9 1 5 Ton N A Up to 9 ft Up to 25 ft 2 7m 7 6m As a guideline add 1 0 oz of R 22 for the heat exchanger plus 1 0 oz for each 10 ft of 1 2 OD refrigerant line if the weighed charge method is used 28g for the heat exchanger plus 9g per meter of 1 2 OD refrigerant line Figure 19 HWG Connection Details Hot water generator service valve assembly inside cabinet SEDES Unbraze u tube Pinch off here after evacuating lineset and opening valves Hot Gas to
63. e of heating or cooling during the construction process The mechanical components and filters will quickly become clogged with construction dirt and debris which may cause system damage Residential Split 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 2007D GENERAL INFORMATION Inspection Upon receipt of the equipment carefully check the shipment against the bill of lading Make sure all units have been received Inspect the packaging of each unit and inspect each unit for damage Insure that the carrier makes proper notation of any shortages or damage on all copies of the freight bill and completes a common carrier inspection report Concealed damage not discovered during unloading must be reported to the carrier within 15 days of receipt of shipment If not filed within 15 days the freight company can deny the claim without recourse Note It is the responsibility of the purchaser to file all necessary claims with the carrier Notify your equipment supplier of all damage within fifteen 15 days of shipment Storage Equipment should be stored in its original packaging in a clean dry area Store units in an upright position at all times Stack units a maximum of 3 units high Unit Protection Cover units on the job site with either the original packaging or an equivalent protective covering Cap the open ends of pipes stored on the job site In areas where painting plastering and or spraying has not been comp
64. e water loop Heat exchangers never fully drain by themselves and will freeze unless winterized with antifreeze Unit Start up Procedure 1 2 3 Turn the thermostat fan position to ON Blower should start Balance air flow at registers Adjust all valves to their full open position Turn on the line power to all heat pump units Room temperature should be within the minimum maximum ranges of Table 11 During start up checks loop water temperature entering the heat pump should be between 30 F 1 C and 95 F 35 Two factors determine the operating limits of water source heat pumps a return air temperature and b water temperature When any one of these factors is at a minimum or maximum level the other factor must be at normal level to insure proper unit operation a Adjust the unit thermostat to the warmest setting Place the thermostat mode switch in the COOL position Slowly reduce thermostat setting until the compressor activates b Check for cool air delivery at the unit grille within a few minutes after the unit has begun to operate Note Units have a five minute time delay in the Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 20070 UNIT START UP PROCEDURE control circuit that can be eliminated on the CXM DXM control board as shown below in Figure 29 See controls description for details c Verify that the compressor is on and that the water flow
65. entered for 20 minutes by shorting the test pins The CXM board will automatically exit test mode after 20 minutes CXM Troubleshooting Process Flowchart Functional Troubleshooting Chart The Troubleshooting Process Flowchart is a quick overview of how to start diagnosing a suspected problem using the fault recognition features of the CXM board The Functional Troubleshooting Chart on the following page is a more comprehensive method for identifying a number of malfunctions that may occur and is not limited to just the CXM controls Within the chart are five columns The Fault column describes the symptoms Columns 2 and 3 identify in which mode the fault is likey to occur heating or cooling The Possible Cause column identifies the most likely Sources of the problem The Solution column describes what should be done to correct the problem WARNING A WARNING HAZARDOUS VOLTAGE DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING Failure to disconnect power before servicing can cause severe personal injury or death Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 20070 CXM PROCESS FLOW CHART WARNING WARNING HAZARDOUS VOLTAGE DISCONNECT ALL ELECTRIC POWER INCLUDING REMOTE DISCONNECTS BEFORE SERVICING Failure to disconnect power before servicing can cause severe personal injury or death CXM Funct
66. epeat and rinse thoroughly with water Evacuation and Charging the Unit LEAK TESTING The refrigeration line set must be pressurized and checked for leaks before evacuating and charging the unit To pressurize the line set attach refrigerant gauges to the service ports and add an inert gas nitrogen or dry carbon dioxide until pressure reaches 60 90 psig 413 620 kPa Never use oxygen or acetylene to pressure test Use a halogen leak tester or a good quality bubble solution to detect leaks on all connections made in the field Check the service valve ports and stem for leaks a leak is found repair it and repeat the above steps For safety reasons do not pressurize system above 150 psig 1034 kPa System is now ready for evacuation and charging Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 20070 REFRIGERATION INSTALLATION Figure 12a Typical Split Air Handler Installation Indoor Compressor Section Power Disconnects Air Handler TXV IN toward Compressor Section Return Plenum Low Voltage Air pad or Extruded polystryene Figure 12b Typical Split Add on Coil Fossil Fuel Furnace Installation Indoor Compressor Section TXV IN toward Compressor Section Power Aad Disconnects A Coil ES 1 PVC Condensate with vented trap Compressor Section Le Air pad or Extruded polystryene Residential Spl
67. er ton 3 9 I m per kw 1 3 1 1 2 6 2 3 For Open Loop Ground Water Systems at 20 26 3 4 3 0 1 5 gpm per ton 2 0 per kw 11 1 14 4 4 3 3 8 Table 12b R 22 Compressor Section Coax Water Pressure Drop Pressure Drop psi 50 F 70 F 0 6 0 5 1 4 1 3 2 0 1 8 2 6 2 4 0 o 5 7 9 A o or Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 20070 Entering Water Suction Pressure PSIG 122 132 122 132 122 132 132 142 132 142 132 142 139 149 139 149 139 149 141 151 141 151 141 151 145 155 145 155 145 155 Suction Pressure PSIG 122 132 121 131 121 131 181 141 130 140 130 140 138 148 137 147 137 147 142 152 142 152 142 152 147 157 147 157 147 157 Suction Pressure PSIG 112 122 111 121 111 121 125 135 123 133 122 132 133 143 132 142 131 141 138 148 137 147 136 146 144 154 143 153 142 152 UNIT OPERATING CONDITIONS Table 14a Size 026 Two Stage R 410A Typical Unit Operating Pressures and Temperatures Full Load Cooling without HWG active Discharge Super Sub Pressure heat cooling PSIG 159 179 13 18 9 14 146 166 13 18 7 12 132 152 7 12 Water Temp Rise F 16 7 18 7 12 3 14 3 7 9 9 9 186 206 172 192 158 178 16 3 18 3 12 1 14 1 7 8 9 8 281 301 267 287 253 273 15 7
68. ermostat wiring check between C and O check for 24VAC on W check between W and C There should be voltage on O but not on W If voltage is present on W thermostat may be bad or wired incorrectly Thermostat wiring Unit Doesn t Operate in Cooling Reversing Valve Thermostat wiring Insufficient capacity Replace or clean Not cooling or heating Reduced or no Air flow Check for dirty air filter and clean or replace properly in heating Check fan motor operation and airflow restrictions Too high of external static Check static vs blower table Reduced or no Air flow Check for dirty air filter and clean or replace in cooling Check fan motor operation and airflow restrictions Too high of external static Check static vs blower table Check supply and return air temperatures at the unit and at Leaky duct work distant duct registers if significantly different duct leaks are present Low refrigerant charge Check superheat and subcooling per chart Restricted metering device Check superheat and subcooling per chart Replace Defective Reversing Valve Perform RV touch test Thermostat improperly located Check location and for air drafts behind stat Recheck loads amp sizing check sensible clg load and heat Unit undersized pump capacity Scaling in water heat exchanger Perform Scaling check and clean if necessary Inlet Water too Hot or Cold Check load loop sizing loop backfill ground moisture High Head Pressure Reduced or no Air flo
69. essor Section Only An external solenoid valve s should be used on ground water installations to shut off flow to the unit when the compressor is not operating A slow closing valve may be required to help reduce water hammer Figure 24 shows typical wiring for a 24VAC external solenoid valve Figures 25 and 26 illustrate typical slow closing water control valve wiring for Taco 500 series ClimateMaster P N AVM and Taco ESP series valves Slow closing valves take approximately 60 seconds to open very little water will flow before 45 seconds Once fully open an end switch allows the compressor to be energized Only relay or triac based electronic thermostats should be used with slow closing valves When wired as shown the slow closing valve will operate properly with the following notations 1 The valve will remain open during a unit lockout 2 The valve will draw approximately 25 35 VA through the Y signal of the thermostat Note This valve can overheat the anticipator of an electromechanical thermostat Therefore only relay or triac based thermostats should be used Two stage Units Two stage units should be designed with two parallel valves for ground water applications to limit water use during first stage operation For example at 1 5 gpm ton 2 0 per kW a model 049 unit requires 6 gpm 23 for full load 2nd stage operation but only 4 gpm 15 during 1st stage operation Since the unit will operate o
70. essor relay will be energized On all subsequent compressor calls the random start delay is omitted Table 9b Unit Operation 50705 50YCS 38WQS 50YCS 38WQS T stat signal Variable Speed Variable Speed PSC Air Handler Air Handler Air Handler G Y or Y1 Stage 1 heating Stage 1 heating Stage 1 heating 1 Stage 1 1st stage compressor 1st stage fan operation Stage 2 2nd stage compressor 2nd stage fan operation Stage 3 2nd stage compressor auxiliary electric heat 2nd or 3rd stage fan operation depending on fan settings 2 Stage 1 1st stage compressor 1st stage fan operation reversing valve Stage 2 2nd stage compressor 2nd stage fan operation reversing valve 3 Stage 1 compressor 1st stage fan operation Stage 2 compressor 2nd stage fan operation Stage 3 compressor auxiliary electric heat 2nd or 3rd stage fan operation depending on fan settings 4 Stage 1 compressor 1st stage fan operation reversing valve Stage 2 compressor 2nd stage fan operation reversing valve 5 Stage 1 compressor fan Stage 2 compressor auxiliary electric heat fan 6 Cooling 2 compressor fan reversing valve Residential Split 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 2007D CXM CONTROLS Table 10 Nominal resistance at various temperatures Temp C Temp F Temp C 1 i78 oo 541 1400 24 9 158 5240 176 49 60 6 212 4460 1508
71. factors is at minimum or maximum levels the other two factors should be at normal levels to insure proper unit operation Extreme variations in temperature and humidity and or corrosive water or air will adversely affect unit performance reliability and service life 2 SOYDSISUYCS 1 imi pu Cooling Heating Cooling Air Limits Min ambient air DB Rated ambient air DB Max ambient air DB Min entering air DB WB Rated entering air DB WB Max entering air DB WB Water Limits Min entering water Normal entering water Max entering water Normal water flow 10 F 23 C 68 F 20 C 85 F 29 C 50 F 10 C 68 F 20 C 80 F 27 C 20 F 6 7 C 30 70 F 1 to 21 C 90 F 32 C 1 5 to 3 0 gpm ton 2 0 to 3 9 per kW Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 20070 UNIT STARTING AND OPERATING CONDITIONS Unit and System Checkout BEFORE POWERING SYSTEM please check the following UNIT CHECKOUT O D O LJ Balancing shutoff valves Insure that all isolation valves are open and water control valves are wired Line voltage and wiring Verify that voltage is within an acceptable range for the unit and wiring and fuses breakers are properly sized Verify that low voltage wiring is complete Unit control transformer Insure that transformer has the properly selected voltage tap
72. gauges unless unit operation appears abnormal Reference the operating charts for pressures and temperatures Verify that air and water flow rates are at proper levels before servicing the refrigerant circuit Residential Split 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 2007D TROUBLESHOOTING General If operational difficulties are encountered perform the preliminary checks below before referring to the troubleshooting charts Verify that the unit is receiving electrical supply power Make sure the fuses in the fused disconnect switches are intact After completing the preliminary checks described above inspect for other obvious problems such as leaking connections broken or disconnected wires etc If everything appears to be in order but the unit still fails to operate properly refer to the CXM Troubleshooting Process Flowchart or Functional Troubleshooting Chart CXM Board CXM board troubleshooting in general is best summarized as simply verifying inputs and outputs After inputs and outputs have been verified board operation is confirmed and the problem must be elsewhere Below are some general guidelines for troubleshooting the CXM control Field Inputs All inputs are 24VAC from the thermostat and can be verified using a volt meter between C and Y G O W 24VAC will be present at the terminal for example between Y and if the thermostat is sending an input to the CXM boa
73. he saturation temperature by using the press temp conversion table on the gauge set 4 Subtract the temperature of Step 3 from the temperature of Step 1 The difference will be the sub cooling value for that unit total degrees below the saturation temperature Refer to Tables 13a or 6b for sub cooling values at specific entering water temperatures Example R 22 refrigerant The condenser pressure at the service port is 225 psig which is equivalent to 110 F saturation temperature Discharge pressure is 236 psig at the compressor 113 F saturation temperature Measured liquid line temperature is 100 F 100 F subtracted from 110 F 10 degrees sub cooling 13 degrees if using the compressor discharge pressure Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 20070 HOT WATER GENERATOR The HWG Hot Water Generator or desuperheater option provides considerable operating cost savings by utilizing excess heat energy from the heat pump to help satisfy domestic hot water requirements The HWG is active throughout the year providing virtually free hot water when the heat pump operates in the cooling mode or hot water at the COP of the heat pump during operation in the heating mode Actual HWG water heating capacities are provided in the appropriate heat pump performance data Indoor compressor section heat pumps equipped with the HWG option include a built in water to refrigerant heat exchanger
74. ic shut off valve DAMAGE WILL OCCUR if shut off valve is closed during unit operation A high pressure switch must be installed on the heat pump side of any field provided shut off valves and connected to the heat pump controls in series with the built in refrigerant circuit high pressure switch to disable compressor operation if water pressure exceeds pressure switch setting The field installed high pressure switch shall have a cut out pressure of 235 psig and a cut in pressure of 190 psig This pressure switch can be ordered from ClimateMaster with a 1 4 internal flare connection as part number 3980005 01 ELECTRICAL THERMOSTAT WIRING Thermostat Installation The thermostat should be located on an interior wall in a larger room away from supply duct drafts DO NOT locate the thermostat in areas subject to sunlight drafts or on external walls The wire access hole behind the thermostat may in certain cases need to be sealed to prevent erroneous temperature measurement Position the thermostat back plate against the wall so that it appears level and so the thermostat wires protrude Figure 28a Typical Thermostat Wiring Two Stage Units 3 Heat 2 Cool From Compressor Solenoid Valve y Notes 1 2 CXM Board Compressor Section Network Interface Modul I Y2 __ ____ 1 FE4 or Other Communicating Indoor Unit User Interface e c ec De
75. ining if the system is ready for charging If the system meets the requirements in Figure 14 it is ready for charging Figure 14 Evacuation Graph 5000 4500 4000 3500 z em e z2000 1500 1000 500 LEAK IN SYSTEM VACUUM TIGHT TOO WET TIGHT DRY SYSTEM 0 T 2 8 A 5 6 7 MINUTES Table 6a R 22 Charging Values A NOTICE NOTICE Use tables 14a to 15 for superheat subcooling values These tables use discharge pressure converted to saturation temperature and liquid line temperature for subcooling calculations If using liquid line pressure subtract 3 F from the table values Charging The System There are two methods of charging a refrigerant system One method is the total charge method where the volume of the system is determined and the refrigerant is measured and added into the evacuated system The other method is the partial charge method where a small initial charge is added to an evacuated system and remaining refrigerant added during operation TOTAL CHARGE METHOD See Table 4 for the compressor section basic charge For line sets with 3 8 liquid lines add 0 6 ounces of refrigerant to the basic charge for every installed foot of liquid line 0 6 grams per cm Add 1 2 oz per foot 1 1 grams per cm if using 1 2 line Once the total charge is determined the factory pre charge Table 4 is subtracted and the remainder is the amount needed to be added to the system This metho
76. intenance or repairs without removing unit Units are typically installed in a mechanical room or closet Never install units in areas subject to freezing or where humidity levels could cause cabinet condensation such as unconditioned spaces subject to 100 outside air Consideration should be given to access for easy removal of service access panels Provide sufficient room to make water electrical and line set connections Any access panel screws that would be difficult to remove after the unit is installed should be removed prior to setting the unit Refer to Figure 2 for an illustration of a typical installation Refer to Physical Dimensions section for dimensional data Conform to the following guidelines when selecting unit location 1 Install the unit on a piece of rubber neoprene or other mounting pad material for sound isolation The pad should be at least 3 8 10mm to 1 2 13mm in thickness Extend the pad beyond all four edges of the unit 2 Provide adequate clearance for maintenance and service Do not block access panels with piping conduit or other materials 3 Provide access for servicing the compressor and coils without removing the unit 4 Provide an unobstructed path to the unit within the closet or mechanical room Space should be sufficient to allow removal of the unit if necessary 5 n limited side access installations pre removal of the control box side mounting screws will allow control box remov
77. ion isolation until the e compressor rides freely on the springs Remove shipping restraints 6 REMOVE COMPRESSOR SUPPORT PLATE 1 4 SHIPPING BOLTS 2 on each side TO MAXIMIZE VIBRATION AND SOUND ATTENUATION R22 indoor units only 7 Locate and verify any hot water generator HWG or other accessory kit located in the compressor section CAUTION CAUTION DO NOT store or install units in corrosive environments or in locations subject to temperature or humidity extremes e g attics garages rooftops etc Corrosive conditions and high temperature or humidity can significantly reduce performance reliability and service life Always move and store units in an upright position Tilting units on their sides may cause equipment damage NOTICE Failure to remove shipping brackets from spring mounted compressors will cause excessive noise and could cause component failure due to added vibration CAUTION CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing safety glasses and gloves when handling parts and servicing heat pumps Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 20070 UNIT PHYSICAL DATA GT PX Two Stage Split BOYDS Series Model 038 09 Compressor 1 Each Copeland UltraTech Two Stage Scroll F
78. ional Troubleshooting Chart Did Unit No Check Main Attempt to power see power Start problems Check fault LED code No fault Siartuo on control board shown See Unit short cycles See Only Yes Only Fan Fan Runs Unit Short Cycles Replace CXM See FP2 See See Over Fault Condensate Under Fault Voltage See Only ves Only Comp Compressor Runs Runs Did unit lockout after a period of operation No Does unit operate in cooling See Does No not Operate in Clg Unit is OK See Performance Troubleshooting for further help Residential Split 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 2007D FUNCTIONAL TROUBLESHOOTING fan ree pee Main power Problems X Green Status LED Off Check Line Voltage circuit breaker and disconnect Check for line voltage between L1 and L2 on the contactor Check for 24VAC between and C on CXM DXM Check primary secondary voltage on transformer HP Fault Code 2 X Reduced no water flow Check pump operation or valve operation setting High pressure in cooling Check water flow adjust to proper flow rate Water Temperature out of range in Bri ter t ithi i t cooling ring water temp within design parameters Reduced or no Air flow Check for dirty air filter and clean or replace in heating Check fan motor operation and airflow restrictions Dirty Air Coil construction dust etc To
79. it 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 20070 REFRIGERATION INSTALLATION Figure 13a Typical Split Air Handler Installation Outdoor Compressor Section RE B Power Compressor Air Handler Section cy Insulated line set _ with UV Paint 0 TXV IN toward compressor 1 __ section 2 Return Plenum 0 Low Volt PVC Wiring di Condensate with vented trap Figure 13b Typical Split Add on Coil Fossil Fuel Furnace Installation Outdoor Compressor Section TXV IN toward compressor section p Power PEN us Disconnects Add On Compressor Coil Section Insulated pz line set with Air UV Paint Temperature Limit Switch Fossil Return Furnace Plenum Low Voltage Wiring Condensate with vented trap Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 2007D REFRIGERATION INSTALLATION Evacuation Of The Lineset And Coil The line set and coil must be evacuated to at least 500 microns to remove any moisture and noncondensables Evacuate the system through both service ports in the shipping position full CW in see table 5 to prevent false readings on the gauge because of pressure drop through Service ports A vacuum gauge or thermistor capable of accurately meausuring the vacuum depth is crucial in determ
80. k to drop below the pump inlet line to avoid air being pumped back out to the earth loop 3 Try to maintain a fluid level in the tank above the return tee so that air cannot be continuously mixed back into the fluid Surges of 50 psi 345 kPa can be used to help purge air pockets by simply shutting off the return valve going into the flush cart reservoir This dead heads the pump to 50 psi 345 kPa To purge dead head the pump until maximum pumping pressure is reached Open the return valve and a pressure surge will be sent through the loop to help purge air pockets from the piping system 4 Notice the drop in fluid level in the flush cart tank when the return valve is shut off If air is adequately purged from the system the level will drop only 1 2 inches 2 5 5 cm in a 10 25 cm diameter PVC flush tank about a half gallon 2 3 liters since liquids are incompressible If the level drops more than this flushing should continue since air is still being compressed in the loop fluid Perform the dead head procedure a number of times Note This fluid level drop is your only indication of air in the loop Antifreeze may be added before during or after the flushing procedure However depending upon which time is chosen antifreeze could be wasted when emptying the flush cart tank See antifreeze section for more details Loop static pressure will fluctuate with the seasons Pressures will be higher in the winter month
81. l can affect efficiency and may not provide the customer with rated or advertised EER and Coil design and technology have dramatically improved operating efficiency and capacity in the past 20 years Homeowners using an older coil are not reaping these cost savings and comfort benefits NEVER MATCH AN R 22 INDOOR COIL WITH AN R 410A COMPRESSOR SECTION Newer indoor coils have a larger surface area enhanced fin design and grooved tubing These features provide a larger area for heat transfer improving efficiency and expanding capacity Typical older coils may only have one third to one half the face area of these redesigned coils Indoor Coil Selection GT PX BOYDS Geothermal Split System Geothermal split system heat pumps are rated in the ARI directory with a specific indoor coil match GT PX Puron split system 50705 models are rated with Carrier Bryant or 4 series variable speed air handlers as shown in Table 1a Other combinations e g variable speed furnace with cased coil may attain the same ARI ratings providing that the specifications meet or exceed those listed in Table 1 AND Table 1b An motor and TXV is required Cap tubes and fixed orifices are not acceptable PSC fans may be used if matched to Table 1b but will not meet ARI ratings If using PSC fan compressor section must be operated as a single stage unit i e wired for either 1st stage or 2nd stage Without the ability to
82. le During UPS warning the alarm relay will cycle on and off The cycle rate will be on for 5 seconds off for 25 seconds on for 5 seconds off for 25 seconds etc UPS warning code 8 Swapped FP1 FP2 thermistors During test mode the control monitors to see if the FP1 and FP2 thermistors are in the appropriate places If the control is in test mode the control will lockout with code 9 after 30 seconds if a The compressor is on in the cooling mode and the FP1 sensor is colder than the FP2 sensor or b The compressor is on in the heating mode and the FP2 sensor is colder than the FP1 sensor Swapped FP1 FP2 thermistor code 9 Diagnostic Features The LED on the CXM board advises the technician of the current status of the CXM control The LED can display either the current CXM mode or the last fault in memory if in test mode If there is no fault in memory the LED will flash Code 1 when in test mode Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 20070 CXM CONTROLS CXM Control Start up Operation The control will not operate until all inputs and safety controls are checked for normal conditions The compressor will have a 5 minute anti short cycle delay at power up The first time after power up that there is a call for compressor the compressor will follow a 5 to 80 second random start delay After the random start delay and anti short cycle delay the compr
83. leted all due precautions must be taken to avoid physical damage to the units and contamination by foreign material Physical damage and contamination may prevent proper start up and may result in costly equipment clean up Examine all pipes fittings and valves before installing any of the system components Remove any dirt or debris found in or on these components Pre Installation Installation Operation and Maintenance instructions are provided with each unit Horizontal equipment is designed for installation above false ceiling or in a ceiling plenum Other unit configurations are typically installed in a mechanical room The installation site chosen should include adequate service clearance around the unit Before unit start up read all manuals and become familiar with the unit and its operation Thoroughly check the system before operation Prepare units for installation as follows 1 Compare the electrical data on the unit nameplate with ordering and shipping information to verify that the correct unit has been shipped 2 Keep the cabinet covered with the original packaging until installation is complete and all plastering painting etc is finished Verify refrigerant tubing is free of kinks or dents and that it does not touch other unit components 4 Inspect all electrical connections Connections must be clean and tight at the terminals 5 Loosen compressor bolts on units equipped with compressor spring vibrat
84. line at a point near the expansion valve bulb 2 Determine the suction pressure by attaching refrigeration gauges to the suction schrader connection at the compressor 3 Convert the pressure obtained in step 2 to saturation temperature boiling point by using the pressure temperature conversion table on the gauge set 4 Subtract the temperature obtained in step 3 from step 1 The difference will be the superheat of the unit or the total number of degrees above saturation temperature Refer to Tables 13a to 14 for superheat ranges at specific entering water conditions Example R 22 refrigerant The temperature of the suction line at the sensing bulb is 50 F The suction pressure at the compressor is 65 psig which is equivalent to 38 F saturation temperature from the R 22 press temp conversion table on the gauge set 38 F subtracted from 50 F 12 F Superheat Determining Sub Cooling 1 Measure the temperature of the liquid line on the smaller refrigerant line liquid line just outside of the cabinet This location will be adequate for measurement in both modes unless a significant temperature drop in the liquid line is anticipated 2 Determine the condensor pressure high side by attaching refrigerant gauges to the schrader connection on the liquid line service valve If the hot gas discharge line of the compressor is used refer to the appropriate column in Tables 13a to 14 3 Convert the pressure obtained in step 2 to t
85. ly to the tank 2 Open a hot water faucet to vent air from the system until water flows from the faucet turn off faucet 3 Depress the hot water tank pressure relief valve handle to ensure that there is no air remaining in the tank 4 Inspect all work for leaks 5 Before restoring power or fuel supply to the water heater adjust the temperature setting on the tank thermostat s to insure maximum utilization of the heat available from the refrigeration system and conserve the most energy On tanks with both upper and lower elements and thermostats the lower element should be turned down to 100 F 38 C or the lowest setting the upper element should be adjusted to 120 130 F 49 54 Depending upon the specific needs of the customer you may want to adjust the upper element differently On tanks with a single thermostat a preheat tank should be used figure 16 6 Replace access cover s and restore power or fuel supply Initial Start Up 1 Make sure all valves in the HWG water circuit are fully open 2 Turn on the heat pump and allow it to run for 10 15 minutes 3 Turn the heat pump and heat pump power supply OFF and CONNECT POWER TO THE HWG PUMP as shown in the unit wiring diagram Connect the pump power lead as instructed on the tag attached to the pump wiring 4 The HWG pump should not run if the compressor is not running 5 The temperature difference between the water entering and leaving the HWG coil should b
86. mpressor Solenoid Valve CXM Board Compressor Section Ye Y1 FV4 TSTAT 1 Air Handler YN2 e 2 1 2 oe e G Re Remove Jumper for Dehum Mode ce DH I DHum 51 52 Notes 1 Thermostat DIP switches must be configured for two speed heat pump 2 Compressor 2nd stage connection is not part of the terminal strip on the CXM board A wire nut connection is required between the compressor solenoid valve and Y Y2 connection at the fan coil Residential Split 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 2007D 50705 UNITS WITH BOARD TYPICAL WIRING DIAGRAM Faso TOYLNOD 1055320990414 9 310N 3 200 0350 10 12 23915 0 541 6 3402 6 3002 5 1 100201 2dd Idd Q3ddVMS 8 3009 2 8 3002 5 1 SdN IQOW 1531 1 3002 9NI 12A2 4 3002 9NIHSV14 3 3095 9 3005 9NIRSV Is XNOHH NI LIV 02 3C0W 1531 83005 8 3002 ANOHEH 11 24 3COW 1531 7 3003 718003 ABOWSH 1713 145 304 1931 3803 3005 AHOWSH NI 110 4 47 300H 1531 4 3005 NI 1 eE 3COW
87. n first stage 80 9096 of the time significant water savings can be realized by using two parallel solenoid valves with two flow regulators In the example above stage one solenoid would be installed with a 4 15 flow regulator on the outlet while stage two would utilize a 2 gpm 8 flow regulator When stage one is operating the second solenoid valve will be closed When stage two is operating both valves will be open allowing full load flow rate Figure 27 illustrates piping for two stage solenoid valves Review figures 24 26 for wiring of stage one valve Stage two valve should be wired between Y2 compressor Solenoid wire nut connection and terminal NOTE When EWT is below 50 F 10 C 2 per ton 2 6 per kW is required Figure 25 AVM Valve Wiring OC Y1 2 AVM EOS eater Switch Taco Valve gt Thermostat Figure 26 Taco ESP Valve Wiring Capacitor End Switch Taco EBV Valve Figure 27 Two Stage Piping Solenoid Valve Flow Regulator Stage 2 To Discharge Stage 1 From Water Source NOTE Shut off valves strainers and other required components not shown Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 2007D A CAUTION A CAUTION Many units installed with a factory or field supplied manual or electr
88. n line Subcooling should be measured using the liquid line temperature immediately outside the compressor section cabinet and either the liquid line service valve pressure or the compressor discharge pressure Note that different values from tables 13a to 14 will be obtained due to the pressure losses through the condenser heat exchanger Adding refrigerant will increase sub cooling while superheat should remain fairly constant allowing for a slight amount of hunting in TXV systems This increase in subcooling will require 5 minutes or so of operation before it should be measured After values are measured compare to the chart and go to FINAL EVALUATION FINAL EVALUATION In a split system cooling subcooling values can be misleading depending on the location of the measurement Therefore it is recommended that charging be monitored in the heating mode Charge should be evaluated by monitoring the subcooling in the heating mode After initial check of heating sub cooling shut off unit and allow to sit 3 5 minutes until pressures equalize Restart unit in the cooling mode and check the cooling superheat against Tables 13a to 14 If unit runs satisfactorily charging is complete If unit does not perform to specifications the cooling TXV air coil side may need to be readjusted if possible until the cooling superheat values are met Checking Superheat and Subcooling Determining Superheat 1 Measure the temperature of the suction
89. n point to the Y input terminal P1 for factory use This Y terminal can be used to drive panel mounted relays such as the loop pump relay Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 20070 UNIT STARTING AND OPERATING CONDITIONS Operating Limits Environment Indoor compressor section is designed for indoor installation only Never install indoor compressor section in areas subject to freezing or where humidity levels could cause cabinet condensation such as unconditioned spaces subject to 10096 outside air Dutdoor unit is designed for conditions where ambient air is below freezing see Table 11 Power Supply A voltage variation of 10 of nameplate utilization voltage is acceptable Starting Conditions Consult Table 11 for the particular model number Starting conditions vary depending upon model number and are based upon the following notes Notes 1 Conditions in Table 11 are not normal or continuous operating conditions Minimum maximum limits are Table 11 Unit Operation start up conditions to bring the building space up to occupancy temperatures Units are not designed to operate under these conditions on a regular basis 2 Voltage utilization range complies with ARI Standard 110 Determination of operating limits is dependent primarily upon three factors 1 return air temperature 2 water temperature and 3 ambient temperature When any one of these
90. ng corrosion prevention and erosion and clogging should be referenced in Table 3 Expansion Tank and Pump Use a closed bladder type expansion tank to minimize mineral formation due to air exposure The expansion tank should be sized to provide at least one minute continuous run time of the pump using its drawdown capacity rating to prevent pump short cycling Discharge water from the unit is not contaminated in any manner and can be disposed of in various ways depending on local building codes e g recharge well storm sewer drain field adjacent stream or pond etc Most local codes forbid the use of sanitary sewer for disposal Consult your local building and zoning department to assure compliance in your area The pump should be sized to handle the home s domestic water load typically 5 9 gpm 23 41 plus the flow rate required for the heat pump Pump sizing and expansion tank must be chosen as complimentary items For example an expansion tank that is too small can causing premature pump failure due to short cycling Variable speed pumping applications should be considered for the inherent energy savings and smaller expansion tank requirements Water Control Valve Note the placement of the water control valve in figure 9 Always maintain water pressure in the heat exchanger by placing the water control valve s on the discharge line to prevent mineral precipitation during the off cycle Pilot operated slow closing valve
91. o high of external static Check static vs blower table Air Temperature out of range in heating Bring return air temp within design parameters Check superheat subcooling vs typical operating condition Overcharged with refrigerant table Bad HP Switch Check switch continuity and operation Replace LP LOC Fault Code 3 Insufficient charge Check for refrigerant leaks Compressor pump down at start Low Pressure Loss of Charge up Check charge and start up water flow FP1 Fault Code 4 Reduced or no water flow Check pump operation or water valve operation setting Water Coil low in heating Plugged strainer or filter Clean or replace temperature init Check water flow adjust to proper flow rate Inadequate anti freeze level Check antifreeze density with hydrometer Improper temperature limit setting eed 30 F vs 10 F 1 C vs 12 C Clip JW3 jumper for antifreeze 10 F 12 C use Water Temperature out of range Bring water temp within design parameters Bad thermistor Check temp and impedance correlation per chart FP2 fault Code 5 Reduced or no Air flow Check for dirty air filter and clean or replace in cooling Check fan motor operation and airflow restrictions AirCoillow Too high of external static Check static vs blower table temperature limit Too much cold vent air Bring entering air temp within Air Temperature out of range design parameters Improper temperature limit setting 30 F vs 10 F
92. ome R 22 service equipment may not be acceptable A CAUTION A CAUTION Installation of a factory supplied liquid line bi directional filter drier is required Never install a suction line filter in the liquid line Line Set Installation Figures 12a through 13b illustrate typical installations with the indoor and outdoor versions of the compressor section matched to either an air handler fan coil or add on furnace coil Table 4 shows typical line set diameters at various lengths Lineset lengths should be kept to a minimum and should always be installed with care to avoid kinking Line sets over 60 feet 18 meters long are not recommended due to potential oil transport problems and excessive pressure drop If the line set is kinked or distorted and it cannot be formed back into its original shape the damaged portion of the line should be replaced A restricted line set will effect the performance of the system A reversible heat pump filter drier is installed on the liquid line inside the compressor section cabinet R 22 units only R 410A models are shipped with a filter drier loose inside the cabinet that must be installed in the liquid line at the line set All brazing should be performed using nitrogen circulating at 2 3 psi 13 8 20 7 kPa to prevent oxidation inside the tubing All linesets should be insulated with a minimum of 1 2 13mm thick closed cell insulation All insulation tubing should be sealed
93. on of iron or galvanized piping or components in the system Open cooling towers requiring heavy chemical treatment and mineral buildup through water use can also contribute to higher maintenance Should periodic coil cleaning be necessary use standard coil cleaning procedures which are compatible with both the heat exchanger material and copper water lines Generally the more water flowing through the unit the less chance for scaling However flow rates over 3 gpm per ton 3 9 per kW can produce water or debris velocities that can erode the heat exchanger wall and ultimately produce leaks Hot Water Generator Coils See water coil maintenance for ground water units If the potable water is hard or not chemically softened the high temperatures of the desuperheater will tend to scale even quicker than the water coil and may need more frequent inspections In areas with extremely hard water a HWG is not recommended Filters Filters must be clean to obtain maximum performance Filters should be inspected every month under normal operating conditions and be replaced when necessary Units should never be operated without a filter Washable high efficiency electrostatic filters when dirty can exhibit a very high pressure drop for the fan motor and reduce air flow resulting in poor performance It is especially important to provide consistent washing of these filters in the opposite direction of the normal air flow once per m
94. onth using a high pressure wash similar to those found at self serve car washes Condensate Drain In areas where airborne bacteria may produce a slimy substance in the drain pan it may be necessary to treat the drain pan chemically with an algaecide approximately every three months to minimize the problem The condensate pan may also need to be cleaned periodically to insure indoor air quality The condensate drain can pick up lint and dirt especially with dirty filters Inspect the drain twice a year to avoid the possibility of plugging and eventual overflow Compressor Conduct annual amperage checks to insure that amp draw is no more than 1096 greater than indicated on the serial plate data Fan Motors Consult air handler 1 for maintentance requirements Air Coil The air coil must be cleaned to obtain maximum performance Check once a year under normal operating conditions and if dirty brush or vacuum clean Care must be taken not to damage the aluminum fins while cleaning CAUTION Fin edges are sharp Cabinet Indoor Compressor Section Do not allow water to stay in contact with the cabinet for long periods of time to prevent corrosion of the cabinet sheet metal Generally cabinets are set up from the floor a few inches 7 8 cm to prevent water from entering the cabinet The cabinet can be cleaned using a mild detergent Refrigerant System To maintain sealed circuit integrity do not install service
95. or Figure 21c R 22 Outdoor Compressor Section Line Voltage Field Wiring 5 Control Low Voltage Connector 208 230 Volt Operation Verify transformer tap with air handler wiring diagram to insure that the transformer tap is set to the correct voltage 208V or 230V ELECTRICAL HWG WIRING HWG Wiring Indoor Compressor Section The hot water generator pump power wiring is disabled at the factory to prevent operating the HWG pump After all HWG piping is completed and air purged from the water piping the pump power wires should be applied to terminals on the HWG power block PB2 as shown in the unit wiring diagram This connection can also serve as a HWG disable when servicing the unit HWG Wiring Outdoor Compressor Section The HWG module should be wired to the outdoor section pump controls see Figure 20 A safety disconnect should be installed at the HWG module to allow servicing of the module If wired as shown any time the compressor is energized the HWG module pump will be activated which will circulate water from the water heater tank to the HWG module DO NOT energize the pump until all HWG piping is completed and air is purged from the water piping to avoid running the pump Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 20070 ELECTRICAL LOW V
96. overy Unit ELECTRICAL LINE VOLTAGE Electrical Line Voltage WARNING All field installed wiring including electrical ground must WARNING To avoid possible injury or death comply with the National Electrical Code as well as all due to electrical shock open the power applicable local codes Refer to the unit electrical data for Bh m fuse sizes Consult wiring diagram for field connections that supply disconnect switch and secure it in an must be made by the installing or electrical contractor open position during installation All final electrical connections must be made with a A CAUTION length of flexible conduit to minimize vibration and sound s transmission to the building CAUTION Use only copper conductors for field installed electrical wiring Unit terminals are not designed to accept other types of conductors Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 20070 ELECTRICAL LINE VOLTAGE Table 8a GT PX Split BOYDS Series Electrical Data Compressor External Min Wire i Circuit Ft LRA FLA Amps m 52 0 4 0 17 3 107 32 7 82 0 4 0 25 3 73 22 3 96 0 4 0 j 30 9 95 29 2 118 0 i 4 0 j 36 4 81 24 8 Rated Voltage of 208 230 60 1 Min Max Voltage of 197 254 HACR circuit breaker in USA only All fuses Class RK 5 Wire length based on one way measurement with 296 voltage drop Wire size based on 60
97. perature for proper range and also verify heating and cooling set points for proper operation System pH Check and adjust water pH if necessary to maintain a level between 6 and 8 5 Proper pH promotes longevity of hoses and fittings see Table 3 System flushing Verify that all air is purged from the System Air in the system can cause poor operation or system corrosion Water used in the system must be potable quality initially and clean of dirt piping slag and strong chemical cleaning agents Some antifreeze solutions may require distilled water Flow Controller pump s Verify that the pump s is wired and in operating condition Q System controls Verify that system controls function and operate in the proper sequence Low water temperature cutout Verify that low water temperature cut out controls are set properly FP1 JW3 Q Miscellaneous Note any questionable aspects of the installation CAUTION CAUTION Verify that ALL water control valves are open and allow water flow prior to engaging the compressor Freezing of the coax or water lines can permanently damage the heat pump NOTICE Failure to remove shipping brackets from spring mounted compressors will cause excessive noise and could cause component failure due to added vibration CAUTION CAUTION avoid equipment damage DO NOT leave system filled in a building without heat during the winter unless antifreeze is added to th
98. rate is correct by measuring pressure drop through the heat exchanger using the P T plugs and comparing to Tables 12a through 12b d Checkthe elevation and cleanliness of the condensate lines Dripping may be a sign of a blocked line Check that the condensate trap is filled to provide a water seal e Referto Table 12 Check the temperature of both entering and leaving water If temperature is within range proceed with the test If temperature is outside of the operating range check refrigerant pressures and compare to Tables 14 and 15 Verify correct water flow by comparing unit pressure drop across the heat exchanger versus the data in Tables 12a through 12b Heat of rejection HR can be calculated and compared to catalog data capacity pages The formula for HR for systems with water is as follows HR TD x GPM x 500 where TD is the temperature difference between the entering and leaving water and GPM is the flow rate in U S GPM determined by comparing the pressure drop across the heat exchanger to Tables 12a through 12b f Check air temperature drop across the air coil when compressor is operating Air temperature drop should be between 15 F and 25 F 8 C and 14 9 Turn thermostat to OFF position hissing noise indicates proper functioning of the reversing valve Allow five 5 minutes between tests for pressure to equalize before beginning heating test a Adjust the thermostat to the lowest setting Place
99. rd Sensor Inputs All sensor inputs are paired wires connecting each component to the board Therefore continuity on pressure switches for example can be checked at the board connector The thermistor resistance should be measured with the connector removed so that only the impedance of the thermistor is measured If desired this reading can be compared to the thermistor resistance chart shown in the CXM DXM AOM manual An ice bath can be used to check calibration of the thermistor Outputs The compressor relay is 24VAC and can be verified using a voltmeter The fan signal is passed through the board to the external fan relay units with PSC motors only The alarm relay can either be 24VAC as shipped or dry contacts for use with DDC controls by clipping the JW1 jumper Electric heat outputs are 24VDC ground sinking and require a volt meter set for DC to verify operation The terminal marked 24VDC is the 24VDC supply to the electric heat board terminal EH1 is stage 1 electric heat terminal EH2 is stage 2 electric heat When electric heat is energized thermostat is sending a W input to the CXM controller there will be 24VDC between terminal 24VDC and EH1 stage 1 electric heat and or stage 2 electric heat A reading of OVDC between 24VDC and EH1 or EH2 will indicate that the board is NOT sending an output signal to the electric heat board Test Mode Test mode can be
100. rsized for space Check sizing for actual load of space Compressor Overload Check and Replace if necessary Unit Short Cycles Unit selection Only Fan Runs Thermostat position Insure thermostat set for heating or cooling operation Unit locked out Check for lockout codes Reset power x Compressor Overload Check compressor overload Replace if necessary Check thermostat wiring at heat pump Jumper Y and R for compressor operation in test mode x Thermostat wiring Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 20070 FUNCTIONAL TROUBLESHOOTING Check G wiring at heat pump Jumper G and R for fan Only Compressor Runs Thermostat wiring operation Jumper G and R for fan operation Check for Line voltage across BR contacts Check fan power enable relay operation if present Fan motor Check for line voltage at motor Check capacitor Fan motor relay Check thermostat wiring at heat pump Jumper Y and R for compressor operation in test mode Set for cooling demand and check 24VAC on RV coil and at CXM DXM board If RV is stuck run high pressure up by reducing water flow and while operating engage and disengage RV coil voltage to push valve Thermostat setup Check for O RV setup not B Check O wiring at heat pump Jumper O and R for RV coil Click iri Put thermostat in cooling mode Check for 24VAC Th
101. s are recommended to reduce water hammer If water hammer persists a mini expansion tank can be mounted on the piping to help absorb the excess hammer shock Insure that the total VA draw of the valve can be supplied by the unit transformer For instance a slow closing valve can draw up to 35VA This can overload smaller 40 50 VA transformers depending on the other controls in the circuit A typical pilot operated solenoid valve draws approximately 15VA see Figure 24 Note the special wiring diagrams for slow closing valves Figures 25 amp 26 Flow Regulation Flow regulation can be accomplished by two methods One method of flow regulation involves simply adjusting the ball valve or water control valve on the discharge line Measure the pressure drop through the unit heat exchanger and determine flow rate from Tables 11a through 11c Since the pressure is constantly varying two pressure gauges may be needed Adjust the valve until the desired flow of 1 5 to 2 gpm per ton 2 0 to 2 6 per kW is achieved A second method of flow control requires a flow control device mounted on the outlet of the water control valve The device is typically a brass fitting with an orifice of rubber or plastic material that is designed to allow a specified flow rate On occasion flow control devices may produce velocity noise that can be reduced by applying some back pressure from the ball valve located on the discharge line Slightly clo
102. s than during the cooling season This fluctuation is normal and should be considered when charging the system initially Run the unit in either heating or cooling for a number of minutes to condition the loop to a homogenous temperature This is a good time for tool cleanup piping insulation etc Then perform final flush and pressurize the loop to a static pressure of 50 75 psi 345 517 kPa winter or 35 40 psi 241 276 kPa summer After pressurization be sure to loosen the plug at the end of the Grundfos loop pump motor s to allow trapped air to be discharged and to insure the motor housing has been flooded This is not required for Taco circulators Insure that the Flow Controller provides adequate flow through the unit by checking pressure drop across the heat exchanger and compare to the pressure drop tables at the back of the manual Antifreeze In areas where minimum entering loop temperatures drop below 40 F 5 C or where piping will be routed through areas subject to freezing antifreeze is required Alcohols and glycols are commonly used as antifreeze however your local sales manager should be consulted for the antifreeze best suited to your area Freeze protection should be maintained to 15 F 9 below the lowest expected entering loop temperature For example if 30 F 1 C is the minimum expected entering loop temperature the leaving loop temperature would be 25 to 22 F 4 to 6 C and freeze protection should
103. shown in Figure 23 to change the setting to 10 F 12 2 C refrigerant temperature a more suitable temperature when using an antifreeze solution All residential units include water refrigerant circuit insulation to prevent internal condensation which is required when operating with entering water temperatures below 59 F 15 Contactor CC Control Voltage Connecto Figure 23 FP1 Limit Setting m BR BRG CCG CC Comp C Relay Off On Test JW3 FP1 jumper should Jw3 4 be clipped for Jw2 amp Epo low temperature CXM PC B operation Residential Split 60Hz R22 4 R410A Geothermal Heat Pumps Rev 28 June 2007D ELECTRICAL LOW VOLTAGE WIRING Accessory Connections A terminal paralleling the compressor contactor coil has been provided on the CXM control Terminal A is designed to control accessory devices such as water valves Note This terminal should be used only with 24 Volt signals and not line voltage Terminal A is energized with the compressor contactor See Figure 24 or the specific unit wiring diagram for details Figure 24 Accessory Wiring Terminal Strip Typical Water Valve 4 O Water Solenoid Valves Indoor Compr
104. sing the valve will spread the pressure drop over both devices lessening the velocity noise NOTE When EWT is below 50 F 10 C 2 gpm per ton 2 6 per kW is required Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 20070 GROUND WATER HEAT PUMP APPLICATIONS Water Coil Low Temperature Limit Setting For all open loop systems the 30 F 1 1 C FP1 setting factory setting water should be used to avoid freeze damage to the unit See Low Water Temperature Cutout Selection in this manual for details on the low limit setting A CAUTION CAUTION Many units installed with a factory or field supplied manual or electric shut off valve DAMAGE WILL OCCUR if shut off valve is closed during unit operation A high pressure switch must be installed on the heat pump side of any field provided shut off valves and connected to the heat pump controls in series with the built in refrigerant circuit high pressure switch to disable compressor operation if water pressure exceeds pressure switch setting The field installed high pressure switch shall have a cut out pressure of 235 psig and a cut in pressure of 190 psig This pressure switch can be ordered with a 1 4 internal flare connection as part number 39 0005 01 A CAUTION A CAUTION Refrigerant pressure activated water regulating valves should never be used with geothermal heat pump equipment Figure 9 Water Well Connections
105. t in death or serious injury CAUTION Indicates a potentially hazardous situation or an unsafe practice which if not avoided could result in minor or moderate injury or product or property damage NOTICE Notification of installation operation or maintenance information which is important but which is not hazard related WARNING A WARNING Verify refrigerant type before proceeding Units are shipped with Puron R410A R22 and R407c refrigerants The unit label will indicate which refrigerant is provided The Puron Application Guideline and Service Manual should be read and understood before attempting to service refrigerant circuits with Puron refrigerant A WARNING A WARNING avoid the release of refrigerant into the atmosphere the refrigerant circuit of this unit must be serviced only by technicians who meet local state and federal proficiency requirements A WARNING A WARNING All refrigerant discharged from this unit must be recovered WITHOUT EXCEPTION Technicians must follow industry accepted guidelines and all local state and federal statutes for the recovery and disposal of refrigerants If a compressor is removed from this unit refrigerant circuit oil will remain in the compressor To avoid leakage of compressor oil refrigerant lines of the compressor must be sealed after it is removed A CAUTION A CAUTION To avoid equipment damage DO NOT use these units as a sourc
106. te proper oil movement and drain down This means that the HWG module can be wall mounted in any orientation except for stubs up Mounting should be accomplished by fastening the HWG module cabinet to the wall or other selected vertical surface A flange is provided at the top rear of the unit Any fastener suitable for supporting a 12 pound 5 4 vertical load is acceptable SPECIAL NOTE The selected mounting location and orientation must allow the circulator pump to be positioned with the motor shaft horizontal DO NOT install the Heat Recovery Unit flat on its back Refrigerant Line Installation Before starting the installation into the refrigerant circuit inspect and note the condition and performance of the heat pump Disconnect power to the heat pump outdoor unit Any system deficiencies must be corrected prior to installing the HWG module Addition of the unit will not correct system problems Record the suction and discharge pressures and compressor amperage draw These will be used for comparison with system operation after the refrigerant line installation is complete and before the water line installation is performed Install the Add On HWG kit using the installation instructions below Locate the HWG as close to the water heater as possible Unbraze the hot gas u bend as shown in Figure 19 Take care to avoid overheating components Install the dual 1 2 lineset to the HWG Maximum length should be 30 feet one way Evacuate th
107. th the air handling unit Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 20070 INSTALLATION Figure 2 5OYDS YCS Installation Air Pad or Extruded polystyrene insulation board Air Pad with access hole External Flow Controller Mounting The Flow Controller can be mounted beside the unit as shown in Figure 7 Review the Flow Controller installation manual for more details Water Connections Residential Distributor Models Residential models utilize swivel piping fittings for water connections that are rated for 450 psi 3101 kPa operating pressure The connections have a rubber gasket seal similar to a garden hose gasket which when mated to the flush end of most 1 threaded male pipe fittings provides a leak free seal without the need for thread sealing tape or joint compound Insure that the rubber seal is in the swivel connector prior to attempting any connection rubber seals are shipped attached to the swivel connector DO NOT OVER TIGHTEN or leaks may occur Line Set Bottom view of Unit 22 x 33 56 x 84cm Existing Pad larger than 22 x 33 54 x 84cm Drill 3 76mm holes for clearance of 1 1 4 32mm pipe Tm with 1 2 13mm wall insulation ej Flow 8 00 Controller 5 5 8 25 14 0cm 21 0cm The female locking ring is threaded onto the pipe threads which holds the male pipe end against the rubber gasket and seals
108. ting mode and bypasses in the cooling mode Heat of Extraction Absorbtion or Heat of Rejection flow rate gpm x temp diff deg F x fluid factor t Btu hr Superheat suction temperature suction saturation temp deg F Subcooling discharge saturation temp liquid line temp deg F tUse 500 for water 485 for antifreeze Note Never connect refrigerant gauges during startup procedures Conduct water side analysis using P T ports to determine water flow and temperature difference If water side analysis shows poor performance refrigerant troubleshooting may be required Connect refrigerant gauges as a last resort Residential Split 60Hz R22 amp R410A Geothermal Heat Pumps Rev 28 June 20070 WARRANTY ARRA 00 44440 044440444440444444440444660 S8IVO ON Hed 90 70 AON 2 0000000000000000000000000000000000000000000000000000000000000 M ah ah P P P P P P ug 9 P9 P P SSS 0 0 0 9 0 0 0 0 9 0 0 00 0 SN SN NN NN S S NN S RN QS suononusur oouvuojureur pue enuey o2ueuojurv q 218 IDeA 01 19 91 5 eourao1d uerpeug pue 0j 9115 AVA qorqA SYFU 19410 Ose Kew pue sjuar 639 oytoeds soeAIS Auer TEM no 0 Ajdde
109. tinuous seconds before de energizing the compressor High pressure lockout code 2 Example 2 quick flashes 10 sec pause 2 quick flashes 10 sec pause etc Low pressure switch The low pressure switch must be open and remain open for 30 continuous seconds during cycle to be recognized as a low pressure fault If the low pressure Switch is open for 30 seconds prior to compressor power up it will be considered a low pressure loss of charge fault The low pressure switch input is bypassed for the initial 60 seconds of a compressor run cycle Low pressure lockout code 3 Water coil low temperature FP1 The FP1 thermistor temperature must be below the selected low temperature limit setting for 30 continuous seconds during a compressor run cycle to be recognized as a FP1 fault The FP1 input is bypassed for the initial 60 seconds of a compressor run cycle FP1 is set at the factory for one try Therefore the control will go into lockout mode once the FP1 fault has occurred FP1 lockout code 4 Air coil low temperature FP2 The FP2 thermistor temperature must be below the selected low temperature limit setting for 30 continuous seconds during a compressor run cycle to be recognized as a FP2 fault The FP2 input is bypassed for the initial 60 seconds of a compressor run cycle FP2 is set at the factory for one try Therefore the control will go into lockout mode once the FP2 fault has occurred
110. tional Electrical Code as well as all applicable local codes Refer to the unit electrical data for fuse sizes Consult wiring diagram for field connections that must be made by the installing or electrical contractor All final electrical connections must be made with a length of flexible conduit to minimize vibration and sound transmission to the building General Line Voltage Wiring Be sure the available power is the same voltage and phase shown on the unit serial plate Line and low voltage wiring must be done in accordance with local codes or the National Electric Code whichever is applicable Power Connection Line voltage connection is made by connecting the incoming line voltage wires to the L side of the contactor as shown in Figures 21a through 21c Consult Tables 8a through 8c for correct fuse size Figure 21a R 410A Compressor Section Line Voltage Field Wiring Unit Power Supply see electrical table for wire and breaker size Figure 21b R 22 Indoor Compressor Section Line Voltage Field Wiring o S fo 8 OS 8 OE Contactor CC Unit Power Supply See electrical table for wire and breaker size Install HWG Pump Power after insuring water is in HWG circuit External Pump Power Supply See electrical table for wire and breaker size Low Voltage Connect
111. toward Mustbe Equalizer compressor section Insulated Line df Add On Heat Pump Applications The indoor coil should be located in the supply side of the furnace to avoid condensation damage to the furnace heat exchanger for add on heat pump applications A high temperature limit switch should be installed as shown in Figures 12b and 13b just upstream of the coil to de energize the compressor any time the furnace is energized to avoid blowing hot air directly into the coil elevating refrigerant pressures during operation The heat pump will trip out on high pressure lockout without some method of disengaging the compressor during furnace operation Alternatively some thermostats with dual fuel mode will automatically de energize the compressor when second stage backup heat is required The TXV should be brazed into place as shown in Figure 11 keeping the IN side toward the compressor section The TXV has an internal check valve and must be installed in the proper direction for operation Always keep the valve body cool with a brazing shield and wet rags to prevent damage to the TXV Attach the bulb to the suction line using the supplied hose clamp Be careful not to overtighten the clamp and deform the bulb NOTICE The air coil should be thoroughly washed with a filming agent dishwasher detergent like Cascade to help condensate drainage Apply a 20 to 1 solution of detergent and water Spray both sides of coil r
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113. w Check for dirty air filter and clean or replace in heating Check fan motor operation and airflow restrictions Too high of external static Check static vs blower table Reduced or no water flow Check pump operation or valve operation setting in cooling Check water flow adjust to proper flow rate Inlet Water too Hot Check load loop sizing loop backfill ground moisture Air Temperature out of range in heating Scaling in water heat exchanger Perform Scaling check and clean if necessary Unit Overcharged Check superheat and subcooling Reweigh in charge Non condensables insystem Vacuum system and reweigh in charge Restricted metering device Check superheat and subcooling per chart Replace Low Suction Pressure Reduced water flow Check pump operation or water valve operation setting in heating Plugged strainer or filter Clean or replace Check water flow adjust to proper flow rate Bring return air temp within design parameters Water Temperature out of range f Bring water temp within design parameters Reduced Air flow Check for dirty air filter and clean or replace in cooling Check fan motor operation and airflow restrictions Too high of external static Check static vs blower table Too much cold vent air Bring entering air temp within design parameters Insufficient charge Check for refrigerant leaks Low discharge alr Too high of air flow Check fan motor speed selection and airflow chart temperature in heating Poor Performance

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